Epoxy coating should be based on carefully selected solvent less Epoxy resin composition. It should be a 3 component system consisting of base, hardener and hard wearing quartz fillers. It should be self levelling composition and forms a very smooth, attractive hygienic, hard wearing and chemical resistant floor topping. It should provides a joint less flooring making it dust free and is easy to clean because of smooth surface. Chemical Resistant – It should have excellent chemical resistance to most chemicals Wear Resistant – It should provide a tough floor topping to withstand foot and light vehicular traffic. 1.2.1.2

Surface Preparation

The long term durability of the applied Epoxy topping is dependent upon the adhesive bond achieved between the flooring material and substrate. It is most important therefore, that substrate surface is correctly prepared prior to application. Substrate must be of sufficient strength to support loads applied through the topping. New concrete or cementitious substrates should have been placed for at least 28 days and have a moisture content of less than 5% before topping. Before application, the surface to 9

be coated should be free from loose particles, rust, oils, grease or earlier coatings and should be thoroughly dry. After surface is dry, all repair work like sealing of joints, cracks filling of cavities and crevices should be carried out. 5. The self levelling action is very localized and does not eradicate irregularities of level present in the original substrate. It is most important, therefore, that adequate surface preparation and repair is undertaken prior to application of flooring systems. 1.2.1.3

Priming

To be as per manufacturer‟s specifications. 1.2.1.4

Mixing

To be as per manufacturer‟s specifications. 1.2.1.5

Laying

Spread the mixture on the floor immediately to the required thickness by means of rollers and serrated trowels. The floor should be rolled by a spike roller to remove trapped air. The floor shall self level to uniform colour and smoothness. 1.2.1.6

Providing & laying in position and compaction as specified machine mixed, plain cement concrete of grade M20 using maximum 20 mm downgraded coarse aggregate using Vacuum Dewatering procedure "TREMIX or Equivalent" including all necessary dewatering, form work, casting in panels of specified size and thickness, wherever necessary, to shape and depth as specified curing, etc., complete for any specified thickness, cutting grooves, filling joints etc. Specification to be inclusive of  Steel form work with steel channel sections as approved by ER/PMC, mechanical vibration using needle and screed vibrators.  Vacuum dewatering and Curing  Cutting mechanically the dummy joints of 6mm wide and up to 0.33 times depth within 24hours - 36 hrs after casting the slab. The dummy joints are at approx 4m x 4m grids.  Filling the grooves for joints with approved primer and approved joint sealing compound. The joint sealant will be filed flush with PCC surface.  The joints will be kept filled with thermocol immediately after cutting and before filling, the same shall be removed & joints cleaned thoroughly with compressed air etc as directed.  The acceptable level difference of VDF shall be only maximum 5mm at entire length. 1.2.4

METAL FIRE DOORS

1.2.3.1 Scope This specification covers the design, supply of materials, Manufacture and installation of factory made special type of approved make steel fire doors of 1 Hour, 2 Hrs. Fire Rating and General Purpose Doors (FD-1 Hr., FD-2 Hr. & G.D.Series) of approved makes. 1.2.3.2 General The Contractor shall furnish all materials, labour, operations, equipment, tools & plant, scaffolding and incidentals necessary and required for the completion of all metal work in connection with steel doors, as called for in the drawings, specifications and bill of quantities which cover the major requirements only. Anything called for in the tender documents shall be considered as applicable to the items of work concerned. The supply and installation of additional fastenings, accessory features and other items not specifically mentioned, but which are necessary to make a complete functioning installation shall form a part of this contract. All metal work shall be free from defects, impairing strength, durability and appearance and shall be of the best quality for purposes specified made with structural proprieties to withstand safety strains, stresses to which they shall normally be subjected to. 12

All fittings shall be of high quality and as specified and as per approval. The Contractor shall strictly follow, at all stages of work, the stipulations contained in the Indian Standard Safety Code or its Equivalent British Standard and the provisions of the safety code and the provision of the safety rules as specified in the General Conditions of the Contract for ensuring safety of men and materials. Any approval, instructions, permission, checking, review, etc., whatsoever by the PMC/AEC, shall not relieve the Contractor of his responsibility and obligation regarding adequacy, correctness, completeness, safety, strength, quality, workmanship, etc. 1.2.3.3 Codes and Standards All standards, specifications, acts, and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions. List of certain important Indian Standards, Acts and Codes applicable to this work is given below. However, the applicable standards and codes shall be as per but not limited to the list given below: IS : 277 Galvanized steel sheet (plain and corrugated) IS : 3614 Metallic and non-metallic fire check doors – Resistance test and Part – 2 performance criteria. 1.2.5

Manufacture Frame to be manufactured from 1.60 mm thick galvanised steel sheet to the specified profiles and dimensions. Frames manufactured at factory shall be knock down form with butt joints for bolted assembly at site. Door frame preparations Frames to be provided with a 3 mm thick back plates on all jambs with provision for anchor bolt fixing to wall openings. All frames to have reinforcement pads for fixing of door closer, at appropriate location as per manufacturer‟s details. Frames to have factory finish-pre-punched cut outs to receive specific hardware and iron mongery. Frames to be provided with hinge plates 3 mm thick pre-drilled to receive hinges for screw mounted fixing. All cut outs including hinge plates, strike plates to have mortar guard covers from inside to prevent cement, dust ingress into cut outs at the time of grouting. Frames to have rubber shutter silencer on strike jambs for single shutter frames and on the head jambs for double shutter frames. Finish Door frames to be suitably cleaned with solvents and etch primered for receiving primer and top coats. Door frames to be primered in zinc phosphate stoving primer (35 microns DFT). Door frames to be finished in thermo setting paint (35 microns DFT) of approved colour and make as specified. 1.2.4.3 Fire Door Shutter Material Fire door shutter to be manufactured from 1.25 mm (18 gauge) galvanized sheets conforming to latest IS : 277 Code or its Equivalent British Standard coating class zinc coating, mill phosphatized. Manufacture Shutters to be press formed to 46 mm thick double skin hollow door with lock seam joints at stile edges. Shutters to have no visible screws or fasteners on either face. Internal reinforcement to be provided at top bottom and stile edges for desired fire rating. Door Shutter Cores Shutters to be provided with honeycomb kraft paper core to be bounded to the inner faces of the shutter. Door shutter preparations

14

Shutters to be factory prepared with pre-punched cutouts and reinforcements to receive iron mongery as per final finish hardware schedule. The shutter should have an interlocking arrangement at this stile edges for flat surface on either side. Shutters to have pre-drilled hinge plates with hinge guard covers. Shutters with locks to have concealed lock box with lock fixing brackets with pre-tapped holes. For shutter with door closer reinforcement pads to be provided at appropriate location as per manufacturer‟s design. All iron mongery preparation to have adequate reinforcement for flushes fixing at site. Vision panel for Fire rated door Vision panel to be provided with Borosilicate clear toughened glass of the thickness 6 mm for up to two hours fire rating. Glass to be fixed with clip on frames for square and rectangular vision panels and with spin turned rings for circular vision panels and Glazing Tape with one side adhesive. Vision Panels to be fixed with clip-on frames for square and rectangular Vision Panels with no visible screws. Unless otherwise specified standard sizes are 200 mm x 300 mm and 360 mm diameter. Finish Shutters to be suitably cleaned with solvents and etch primered for receiving primer and top coats. Shutters to be primered in zinc phosphate stoving primer (35 microns DFT). Shutters to be finished in thermo setting paint (35 microns DFT) of approved colour and make as specified. 1.2.4.4 Installation Door frame fixing The door frames should be assembled adjacent to the place of installation as the frames are not designed for transporting in an assembled condition. After assembly it is to be ensured that all threaded preparations are covered from the back of the frame using self adhesive strip to prevent penetration of mortar back-fill into screw threads. The head member of assembled frame shall be positioned against jambs ensuring correct alignment and secured using M8 x 20 long plated bolts together with nuts spring and flat washers. The assembled frame shall be kept in position within the opening by means of bracing. In order to correctly position the frame against finished floor level or equalise on adjustable floor anchors where specified, shim shall be used under jambs. The frame shall be checked for squareness, alignment, twist etc. with carpenters bevel and plumb. A tie rod shall be fixed to the frame during installation to ensure the correct dimensions between the frame rebated and the same may be removed after installation. Where a 2nd fix application is required a shim detail is suggested to take up gap between frame and existing opening. Existing masonry wall openings – Metal expansion shields  Brace, position, level etc.  Mark all positions of fixings on wall. 15

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Remove frame and drill wall to appropriate specified size. Fit rod anchor shells metal expansion bolts into the wall. Fit jamb spacer bracket into back of frame profile. Reposition frame back into opening and realign. Lightly screw CSK HD machine screws into shells, shim behind frame. Slowly tighten screws continually checking plumb, square etc. Finally ensure frames are not deformed as tightened. After fixing the frame shall be grouted with cement mortar 1:3 or Plaster of Paris or Gypsum powder as approved. Gap between frame and wall to be closed by cement pointing using cement mortar 1:3. Back full the frame through holes provided and insert nylon plugs.

Door shutter fixing  Fix all the hardware to the door shutter like hinges, flush bolts, bolts, mortise locks, door closer, door stoppers, handles etc. with the appropriate screws and bolts supplied.  The shutter is to be then fixed to the frame which is already installed. Align the shutter to match the hardware to the cutouts in the frame. Tighten the hinge screws.  Application of Fire / Smoke UL 10 C / UL 1784 (2001) classified seal (for smoke check if specifically required)  Clean door jamb rebate surfaces of all dust, oil etc. Affix self-adhesive Fire / Smoke seal on the door frame rebates as indicated by the manufacturer on hinge jambs, strike jambs, head member and sill.  2 Hours FIRE RATED DOOR – Hardware Schedule: All hardware to be in line with door schedule drawing. 1.2.6

HOLLOW METAL FIRE DOOR1 HOUR FIRE RATING) WITH HONEY COMB CORE

1.2.5.1 General Unless otherwise specified, maximum size of door in this type: Single shutter door : 1200 mm x 2200 mm Double shutter door : 2000 mm x 2200mm For doors of size above 2200 mm height the options shall be: A man operation door of size above 2049 mm height shall be provided with a removable panel / fixed panel on top with glazing or without glazing or without glazing as required. The construction of above panel shall be designed similar to that of a shutter in case of flush panel to match the exteriors. 1.2.5.2 Frame Material

Manufacture Frame to be manufactured from 1.25 mm thick galvanised steel sheet to the specified profiles and dimensions. Frames manufactured at factory shall be knock down form with butt joints for bolted assembly at site. Door frame preparations Frames to be provided with a 3 mm thick back plates on all jambs with provision for anchor bolt fixing to wall openings. All frames to have reinforcement pads for fixing of door closer, at appropriate location as per manufacturer‟s details. Frames to have factory finish-pre-punched cut outs to receive specific hardware and ironmongery. Frames to be provided with hinge plates 3 mm thick pre-drilled to receive hinges for screw mounted fixing. All cut outs including hinge plates, strike plates to have mortar guard covers from inside to prevent cement, dust ingress into cut outs at the time of grouting. Frames to have rubber shutter silencer on strike jambs for single shutter frames and on the head jambs for double shutter frames. Finish Door frames to be suitably cleaned with solvents and etch primered for receiving primer and top coats. Door frames to be primered in zinc phosphate stoving primer (35 microns DFT). Door frames to be finished in thermo setting paint (35 microns DFT) of approved colour and make as specified. 1.2.5.3 Door Shutter Material General purpose door shutter to be manufactured from 0.80 mm (22 gauge) glavanised sheets conforming to latest IS : 277 Code or its Equivalent British Standard coating class zinc coating, mill phosphatized. Manufacture Shutters to be press formed to 46 mm thick double skin hollow door with lock seam joints at stile edges. Shutters to have no visible screws or fasteners on either face. Door shutter core

17

Shutters to be provided with honeycomb paper cored to be bounded to the inner faces of the shutter. Door shutter preparations  Shutters to be factory prepared with pre-punched cutouts and reinforcements to receive iron mongery as per final finish hardware schedule. The shutter should have an interlocking arrangement at this stile edges for flat surface on either side.  Shutters to have pre-drilled hinge plates with hinge guard covers. Shutters with locks to have concealed lock box with lock fixing brackets with pre-tapped holes.  All iron mongery preparation to have adequate reinforcement for flush fixing at site.  For shutter with door closer reinforcement pads to be provided at appropriate location as per manufacturer‟s design. Vision panel Vision panel to be provided with Borosilicate clear toughened glass of the thickness 6 mm for up to two hours fire rating. Glass to be fixed with clip on frames for square and rectangular vision panels and with spin turned rings for circular vision panels and Glazing Tape with one side adhesive. Vision Panels to be fixed with clip-on frames for square and rectangular Vision Panels with no visible screws. Unless otherwise specified standard sizes are 200 mm x 300 mm and 360 mm diameter. Finish Shutters to be suitably cleaned with solvents and etch primered for receiving primer and top coats. Shutters to be primered in zinc phosphate stoving primer (35 microns DFT). Shutters to be finished in thermo setting paint (35 microns DFT) of approved colour and make as specified. All hardwares to be as per the detail drawing. 1.2.5.4 Installation Door frame fixing  The door frames should be assembled adjacent to the place of installation as the frames are not designed for transporting in an assembled condition. After assembly it is to be ensured that all threaded preparations are covered from the back of the frame using self adhesive strip to prevent penetration of mortar backfill into screw threads. The head member of assembled frame shall be positioned against jambs ensuring correct alignment and secured using M8 x 20 long plated bolts together with nuts spring and flat washers.  The assembled frame shall be kept in position within the opening by means of bracing. In order to correctly position the frame against finished floor level or equalise on adjustable floor anchors where specified, shim shall be used under jambs. The frame shall be checked for squareness, alignment, twist etc. with carpenters bevel and plumb.

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A tie rod shall be fixed to the frame during installation to ensure the correct dimensions between the frame rebated and the same may be removed after installation. Where a 2nd fix application is required a shim detail is suggested to take up gap between frame and existing opening.

Repeat rinse as above, and wipe surface dry with soft cloth until surfaces are spotless and dry.

1.2.6.8 PROTECTION OF INSTALLED PRODUCTS  Immediately after cleaning, cover polycarbonate sheet glazing surfaces with polyethylene sheeting, or other covering material approved by polycarbonate sheet manufacturer; secure covering in place by taping to framing members - do not tape covering to polycarbonate sheet materials.  Protect installed glazing from damage to function or finish by subsequent construction activities.  Repair minor damage to finishes in accordance with polycarbonate sheet manufacturer's recommendations.  Replace glazing having damage to function, and glazing having damage to finishes 1.2.8

GRC [ GLASS REINFORCED CONCRETE ] WORKS

1.2.7.1 Scope The specifications refer to GRC [Glass Reinforced Concrete] works in the building. 1.2.7.2 Specialist Contractor The work specified in this section is to be undertaken by a Manufacturer who is a Member of the National Precast Concrete Association Australia, GRC Industry Group with experience in the GRC industry, which includes the production of architectural panels (or other products for which this specification is being used). With his tender, the contractor shall submit to the construction manager written evidence indicating his capability of producing panels of a reliable and consistent quality. 1.2.7.3 Standards and Codes AS 3972 BS 1 BS 3892 BS 476 Part 8

Portland and blended cements. Portland Cement. Pulverised Fuel Ash for use in Concrete. Test Methods and Criteria for the Fire Resistance of Elements of Building Construction. GRC Industry Group of National Precast Concrete Association Australia, A Recommended Practice – Design, Manufacture and Installation of Glass Reinforced Concrete (GRC) AS 3582.1 Supplementary cementitious materials for use with portland and blended cement - Fly ash. AS 1130 Code of practice for use of fly ash in concrete. AS/NZS 1170.1 Structural design actions – Permanent, imposed and other actions. AS/NZS 1170.2 Structural design actions – Wind actions. AS 1170.4 Minimum design loads on structures (known as the SAA Loading 23

1.2.7.4 MATERIALS General & Codes Materials used for making the GRC unit shall generally comply with relevant British and Australian Standards and Codes. Any reference to a British Standard shall mean that current at the time of going to tender. Where materials are not fully covered by this specification or alternative materials are offered, the Contractor shall forward to the Construction Manager prior to commencing the work, details of those he proposes to use together with supporting evidence indicating that the finished product will be capable of meeting the performance requirements of this specification. Alkali-Resistant Glassfibre Glass fibre shall be an alkali-resistant, continuous filament fibre developed and formulated specifically to have high strength retention in Ordinary Portland Cement environments. The glass fibre shall have a minimum ZrO2 content of 16% by weight, in accordance with internationally-recognised standards, and shall have a minimum strength retention (determined by Strand In Cement (SIC) testing) of 300 MPa (Test Method: GRCA SO 104/0184). The producer shall provide certification from the glassfibre manufacturer to show that the glass fibre conforms to these requirements, has a history of successful use in similar matrices, and is manufactured under an internationally-recognised Quality Management system. Suitable alkali-resistant glassfibres are “Cem-FIL“, manufactured by SaintGobain/Vetrotex and “NEG ARG Fibre” manufactured by Nippon Electric Glass. Cement The cement shall be Ordinary Portland Cement, supplied by a manufacturer of assessed capability to AS 3972– 1997 and BS 12 or its derivatives, and should be supported by suitable certification. Cement shall be obtained from one source throughout manufacture. Cement shall be correctly stored and kept dry to avoid deterioration. Sand Sands should be washed and dried to remove soluble matter, and to permit control of the water/cement ratio. Sand added to the mix shall not exceed 50% by weight of the total

24

mix and sand/cement ratio shall not exceed 1:2. Sand shall be only high silica and conform to the following specification: Silica content > 967% Water content < 2% Soluble salts < 1% Grain size < 1.2 mm < 10% passing a 150 micron sieve Sands other than silica sands may be used subject to approval of the architect and engineer, but the producer must be able to show proof of their suitability. Admixtures The manufacturer shall ensure that any admixtures used do not have any harmful effects on the product, and are used in accordance with the manufacturers‟ recommendations. The use of superplasticisers may be encouraged to keep water content of the composite to a minimum without loss of suitable working characteristics, especially the ease of attaining full compaction. Any admixtures used, shall comply with AS 1478. Pigments Any pigments used shall conform to BS 1014. These shall be:  Harmless to the GRC‟s set and strength.  Stable at high temperature.  UV-resistant and alkali-resistant. The client should recognise that some colour variation may occur, and must agree an acceptable range of variation with the producer. Water Water shall be free from deleterious matter that may interfere with the colour, setting, or strength of the concrete. Mix Design The mix shall have been determined by the manufacturer, and written confirmation of the mix design shall be submitted so the proportions shall be chosen to achieve the qualitycontrol requirements specified herein. Mould-Release Agent The mould-release agent shall be selected by the manufacturer and approved by the architect or engineer. This should be compatible with the surface finish required for the product. Any residue shall be removed from the finished product so that this does not interfere with any joint sealants or applied finishes which may be used. Formwork The design, material and manufacture of the forms shall be consistent with the type and quality of the surface finish required from the panel, and with the tolerances specified. The forms shall be constructed such that the finished products conform to the profiles and dimensions indicated by the contract documents. 25

Support Steelwork and Fixings  The Manufacturer will be responsible for the design, manufacture and installation of all support framing, cleats and fixings inserted into and affixed to the GRC panels, or provided for the support of the GRC panels. Fixing zones are described on the drawings, together with primary structural concrete and steelwork provided by others for use by the contractor if required.  Fixings shall be concealed and cast into panels unless otherwise specified. They shall be of non-corrosive material and located at suitable spacings to ensure support of panels without creating undue stresses to the panels under thermal movements and/or moisture movement.  The recommendations of the Recommended Practice – Design, Manufacture and Installation of GRC – NPCAA Publication, August 1999 (herein after called NPCAA Recomended Practice) shall be incorporated in the design of fixings.  Steel materials and workmanship shall comply with the relevant codes, and all steel will be free from rust, loose scale, pitting and other defects.  Fabricated steel components shall be true to line and free from twists, bends and open joints.  All ungalvanised materials shall be thoroughly cleaned prior to fabrication, by grit blasting to Class 2 in accordance with AS 1627 Part 4 and painted with Red Oxide Zinc Chromate in two coats to a minimum dry film thickness of 80 microns.  Fixing cleats to existing steelwork, where indicated on the GRC cladding shop drawings, shall be site-welded unless otherwise arranged with the construction manager.  Any damage to protective coatings on steelwork, supplied as part of this contract works, shall be repaired. 1.2.7.5 WORKMANSHIP Weighing and Batching Dry ingredients shall be batched by weight using calibrated weighing equipment capable of an accuracy of ± 2% of the stated batch weight. Liquids should be weighed, volumebatched or automatically dispensed. The producer must demonstrate that the method employed will give an accuracy of ± 2%. Mixing The cement slurry should be mixed in a high-speed shear mixer, or other high-speed mixer which can achieve a good and even dispersion of all slurry ingredients. Application  Application shall be by spraying, using purpose-built equipment which allows the simultaneous deposition and uniform mixing of the glassfibre and cement matrix.  The glassfibre and cement slurry shall be metered to the spray head at rates to achieve the desired mix proportion and glass content. These shall be checked for each spray pump at least once per day and prior to commencing spray production 26

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after each stoppage. The test shall be conducted in accordance with the method described in BS EN 1170-3. Distribution of fibre in the mix shall be controlled by the operator in such a way as to be as uniform as possible. Cleanliness of equipment and working areas shall be maintained at all times.

Shape and Finish  The panels are to be formed of GRC in moulds to achieve the profiles indicated by the architectural drawings.  The manufacturer shall provide a means for producing a replacement panel at any time during the building contract. Moulds shall be adequately cured to eliminate shrinkage and distortion and shall be properly braced.  The exposed face of the GRC panels surfaces shall be free of blowholes, cracks, undulation or similar imperfections. Manufacture  The panels shall be manufactured by a spray technique as detailed in the NPCAA Recommended Practice or as otherwise agreed between the manufacturer and architect/engineer to an approved method.  Spray applicators shall be experienced personnel whose proficiency meets industry standards.  If an architectural face mix is being used, this will first be sprayed into the mould. The thickness shall generally be the minimum possible to achieve the desired finish, which will normally make it at least 20% thicker than the largest sand or aggregate being used and normally 4 mm minimum and 12 mm maximum thickness. An acrylic polymer should be used in the face mix to reduce any risk of this unreinforced layer cracking.  If no face mix is being used, a mist coat consisting of the basic mortar composition without fibre may, if necessary, be sprayed onto the moulds to prevent fibres from being visible on the finished surface of the product. The mist coat is intended to be just thick enough to cover mould details and surfaces so that fibres are not visible on the surface, but not so thick that crazing of this unreinforced layer may occur.  The normal target thickness of a mist coat for non-polymer GRC is 1 mm, though the use of acrylic polymer in the mix may allow the thickness to be increased up to a maximum of 3 mm. However, it should be noted that for design purposes the thickness of the mist coat should not be considered as contributing to the strength of the GRC panel.  Spray-up of GRC backing material shall proceed before any mist coat or face mix has set.  The method of spraying the main body of material shall achieve the greatest possible uniformity of thickness and fibre distribution.  Consolidation shall be by rolling and such other techniques as are necessary to achieve complete encapsulation of fibres and full compaction.

27

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Control of thickness shall be achieved by using a pingauge or other acceptable method. Minimum thickness of panels is recommended as 8 mm (hand-spray) and 6 mm (auto-spray). All hand-forming of intricate details, incorporation of formers of infill materials and over-spraying shall be carried out before the material has achieved its initial set so as to ensure complete bonding. Inserts shall be properly embedded into thickened, homogeneous areas of GRC. Waste material such as over-spray is not acceptable to encapsulate inserts or for bonding pads. Any rigid embedded items bonded to the GRC shall not create undesirable restraint to volume changes.

Shop Drawings  Prior to commencing manufacturing work, the manufacturer shall submit for approval detailed shop drawings showing the following information:  layout (sectional plan and elevation) of complete wall panelling;  full-size section of typical panel and support members;  method of assembly and supports and fixings to the existing structure and provision to withstand imposed stresses;  method of installation, caulking, flashing and provision for vertical and horizontal expansion;  junction and trim to adjoining surfaces; and  fittings and accessories,  The submission of shop drawings shall be supported by engineering design computations to show that cladding and supports comply with the design criteria specified. Tolerances The GRC elements shall be manufactured and installed to the tolerances stated in the NPCAA Recommended Practice (Section 10). Demoulding and Curing  Once the initial set has taken place, GRC elements should be covered with polythene for their protection and to prevent them from drying out fully. They must not be moved again until they are ready for demoulding.  The GRC elements must not be demoulded until they have gained sufficient strength to be removed from the mould and transported within the factory, without being overstressed.  If the GRC elements are too large to be demoulded by hand, special demoulding sockets or loops should be embedded in the panel during manufacture, and demoulding should be assisted with a lifting frame. This procedure should be agreed with the engineer.  During demoulding, the panels shall be uniformly supported in a manner which avoids undue stresses in the panels.  If polymers are used in the mix to avoid wet curing, the panels should be stored under cover for a minimum of 7 days at a temperature of between 5°C and 35°C. 28

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If polymers are not used in the mix, curing shall be continued after demoulding under conditions which shall provide free water on the surfaces of the panels at a temperature not exceeding 50°C for a period of not less than 7 days (including the initial cure in the mould).

Identification of Elements All panels shall be identified individually to indicate the panel type and date of manufacture. At the time of preparation of shop drawings the manufacturer shall indicate his required order of delivery. Handling, Transportation and Installation The products shall be handled, transported and installed using methods which ensure that no damage or marking of architectural surfaces occurs and so that the panels are not subject to undue stress. The safety and protection of GRC units shall be ensured throughout the whole of the contract works. Site access and, if necessary, storage space shall be provided by the main contractor. The main contractor shall also provide true, level and clean support surfaces and shall provide for the accurate placement and alignment of connection hardware on the structure. Test Requirements The specified glass fibre content shall be 5% by total wet weight of materials. The GRC from which the panels are made shall have the following properties on completion of curing:  Characteristic Modulus of Rupture (MOR) 18 MPa at 28 days.  Characteristic Limit of Proportionality (LOP) 7 MPa at 28 days. The value of MOR and LOP design stresses to be used should be determined by the design engineer for specific service requirements. The minimum dry density shall exceed 1800 kg/m3. Tests The following tests shall be carried out on coupons cut from the test boards in accordance with BS EN 1170 Parts 2, 4, and 5. If acrylic polymer is used in the mix, presoaking immediately prior to testing shall not be required for Modulus of Rupture or Limit of Proportionality.  Glass Content – BS EN 1170 Part 2  Modulus of Rupture – BS EN 1170 Part 5 (and simplified method in Part 4)  Limit of Proportionality. – BS EN 1170 Part 5 Test boards shall be produced alongside each day‟s production (at least one per day for each production team). The recommended size of these sample boards is 600 x 600 mm. The test boards shall be produced with the same quality, thickness and curing as the actual panels. Those test boards which are not required for testing should be kept for the duration of the contract, or for a period to be agreed between the manufacturer and engineer. 29

Frequency of Testing The frequency of testing shall be agreed between the architect, engineer and manufacturer. The recommendation of BS EN 1169 is as follows:  Glass content – tested in accordance with BS EN 1170 Part 2. Once per week for each spray team. (This is in addition to the calibration test referred to in section 3.3).  Modulus of Rupture and Limit of Proportionality – tested in accordance with BS EN 1170 Part 5. Should be tested by the manufacturer or by a qualified laboratory as the mix design is being set-up and thereafter at least twice per year, or when the mix design is changed.  A simplified bending strength test to determine the Modulus of Rupture (MOR) should be conducted by the manufacturer more frequently The frequency of testing recommended by BS EN 1169 is for each 10 tonnes of GRC produced, or at least once per week.  Water Absorption and Dry Density – tested in accordance with BS EN 1170 Part 6. As the mix design is being set-up, and then for each 10 tonnes of GRC produced, or at least once per week. Compliance Compliance with glass content and the characteristic strength for both LOP and MOR shall be assumed if the following conditions are met:  Glass Content : The glass content shall not vary from the specific amount by more than ± 20%.  Modulus of Rupture and Limit of Proportionality : The characteristic MOR and LOP is defined as the value which 95 per cent of all the mean strengths of the individual test-boards shall exceed.  Compliance with the characteristic MOR and LOP requirements shall be assumed if no single test-board mean shall be less than 85 per cent of the characteristic MOR and LOP, and the average of 4 consecutive test board results shall exceed 21 MPa (MOR), and 8 MPa (LOP).  If any single test-board fails to meet any of the compliance requirements, the GRC at risk shall be that produced between the previous complying test board and the next complying test board.  Where failure to comply arises from consideration of consecutive groups of four test-boards, the GRC at risk shall be that represented by the first and fourth testboards, together with all intervening material.  Note: If different values for MOR and LOP are required for specific service requirements, these should be determined by the design engineer for the specific service requirements. The selection of unnecessarily high strength requirements may result in cost penalties.  Dry Density : The dry density of the GRC shall exceed 1800 kg/m3.  Non-Compliance : In the event of non-compliance, the action to be taken should be agreed between the manufacturer and the client. Due regard should be paid to the technical consequences of the non-compliance and the economic 30



consequences of adopting remedial measures or replacing the rejected products. Account should also be taken of the safety factors incorporated in the design and also the thickness of the GRC produced, compared with the design thickness. Retesting may be considered appropriate if it is considered that the storage conditions of the product may result in improved properties because of extended curing, or if the sampling, testing or calculation may have been at fault. The material at risk may be reduced by the testing of additional test boards from the same, previous, or next manufacturing periods. Testing may also be performed on GRC samples cut from the actual GRC elements at risk.

Weatherproofing  Responsibility for the weatherproofing of the whole installation of GRC panels rests with the GRC manufacturer.  The joint details shown on the drawings represent the appearance required and their minimum standard of weatherproofing acceptable.  Joints shall be weather-sealed with closed-cell polyethylene compressible backing rods and caulked with 2-part polysulphide sealant or other approved sealant in selected colours, installed completely in accordance with the sealant manufacturer‟s recommendations with regard to joint dimension, priming, substrates, mixing, curing, masking, cleaning and the like.  The GRC manufacturer shall submit details of the proposed sealant and the application recommendations for approval by the construction manager prior to commencement of the contract works.  Joints located and indicated on the drawings are those required for sealing the GRC cladding against adjacent materials and those required for architectural purposes for division of the panels into the design modules. Should the GRC manufacturer or contractor propose to subdivide the cladding into smaller panels for ease of casting, handling and erection, additional joints may be introduced in the design, provided the location proposed is discreet. The GRC manufacturer shall submit proposed locations and designs of additional panel joints with their tender submission. 1.2.7.6 Other Issues Responsibility The GRC manufacture shall be solely responsible for the design and performance of the GRC panels and their supports. Information provided on the drawings or this specification shall not affect this responsibility. Guarantees The Manufacturer shall warrant the GRC panels installed, or to be installed, against any and every defect or failure which may occur during the period of practical completion for the works arising out of any fault of the GRC cladding system, workmanship, fabrication, fixing or quality of materials used. Design Criteria 31

   

1.2.9

Glassfibre-reinforced wall cladding shall comply with the following: FINISH : Class 1 to the formwork code, smooth face suitable for high paint finish. DESIGN LOADS : Cladding and framing shall be designed in accordance with AS1170. DEFLECTIONS OF MAIN FRAME STEEL MEMBERS: The attention of the contractor is drawn to the allowance made for differential deflections between the structure at level 2 and the ground. The anticipated allowance is 30 mm. The detailing of the GRC cladding should take this into account PARTITION WORKS

1.2.8.1 Scope This specification covers the general requirements for fabrication and erection of wooden / aluminum / gypsum board partitions and other related works forming a part of this job, which may be required to be carried out though not specifically mentioned above. The work under this specification shall consist of furnishing of all tools, labour, materials and everything necessary for carrying out the work. 1.2.8.2 Applicable Codes and Standards Work shall be carried out as per latest edition of Indian Standards and Code of Practices. List given here shall not be considered as conclusive and is for reference and guidance only. Any discrepancies/ conflict noticed shall be brought to the notice of Architect/Engineer in charge for direction / approval. However, as a general rule more stringent specification shall take precedence. IS: 287 Permissible moisture content for timber used for different purposes. IS: 303 Plywood for general purpose IS: 710 Marine plywood IS: 733 Wrought aluminum and aluminum alloys, bars, rods and sections for general engineering purposes. IS: 848 Synthetic resin adhesive for plywood IS: 1200 Method of measurement of building and civil engineering works. IS: 1328 Veneered decorative plywood IS: 1868 Anodic coating on aluminum and its alloys. IS: 1948 Aluminum doors, windows and ventilators IS: 1949 Aluminum windows for industrial buildings IS: 2095 Gypsum plaster boards IS: 2191 Plywood face panels IS: 2542 Method of test for gypsum plaster IS: 2835 Flat transparent sheet glass IS: 3144 Methods of test for mineral wool thermal insulation materials IS: 3513 Resin treated compressed wood laminates IS: 3677 Unbonded rock and slag wool for thermal insulation IS: 4021 Timber door, window and ventilator frames IS: 5509 Fire retardant plywood IS: 5523 Methods of testing anodic coatings on aluminum 32

1.2.8.3 Aluminium Partitions Materials  Aluminium alloy used in the manufacture of extruded sections for the fabrication of doors, windows, ventilators shall conform to designation 63400 WP of IS:733.  Transparent sheet glass shall conform to the requirements of IS: 2835. Wired and figured glass shall be as per IS: 5437.  Builder's hardware of fittings & fixtures shall be of the best quality from approved manufacturers. Workmanship  All aluminium partitions shall be of the type as specified in the respective items of work and of sizes as indicated in the drawings.  All aluminium units shall be supplied with anodized/powder coated finish. The minimum anodic film thickness shall be 0.015 mm.  Aluminium partitions shall be as described in the item of work and/or bid drawings which indicate generally the arrangement along with the overall size of the various components and weight per running meter of the extruded sections to be adopted.  IS:1948 and IS:1949 are referred to incorporate the sizes, shapes, thicknesses and weight per running meter of extruded sections for the various components of the units. However, new sizes, shapes, thicknesses with modifications to suit snap-fit glazing clips etc. are continuously being added by various leading manufacturers of extruded sections, which are available in the market. As such, the sections of the various components of the unit proposed by the CONTRACTOR, will be reviewed by the ENGINEER and will be accepted only if they are equal to or marginally more than that specified in the codes/ item of works.  The framework of the partitions with mullions and transoms shall be with anodized/powder coated aluminium extruded sections of dimensions as per the item of work. Anodized/powder coated Aluminium extruded sections shall be infilled with timber of class 3 (silver oak or any other equivalent) as per IS:4021. Panels of double/single glazing/plywood shall be fixed as per details indicated in the drawing. Partitions shall be fixed rigidly between the floor and the structural columns/beams including provision of necessary shims for wedging etc. Finished work shall be of rigid construction, erected truly plumb to the lines and levels, at locations as per the construction drawings.  Specific provisions as stipulated for steel doors, windows, ventilators shall also be applicable for this item work. Glazing beads shall be of the snap-fit type suitable for the thickness of glazing proposed as indicated in the item of work. A layer of clear transparent lacquer shall be applied on aluminium sections to protect them

33

from damage during installation. This lacquer coating shall be removed after the installation is completed.

34

TECHNICAL SPECIFICATION CIVIL WORKS

35

CIVIL WORKS 2.1 RUBBLE SOLING WORK 2.1.1 Scope This specification covers general requirements for materials to be used for carrying out rubble soling including requirements in regard to the quality & placement of rubble soling. This also covers the compaction of surfaces for level & profile thereof. 2.1.2 General Area receiving soling will be excavated and trimmed to the required levels, profile, gradient, if any, and the same shall be rolled / compacted thoroughly, as approved by the ENGINEER. 2.1.3 Material Specification Stone for soling work shall be black stone of good quality of specified size with minimum size variation. It shall be free from impurities and foreign matter. 2.1.4 Workmanship & Construction 2.5.1 2.5.2 2.5.3

2.5.4

The Soling shall not be constructed on a wet surface. Unless otherwise specified, the width of the soling stone shall be 230 mm and the finished soling course thickness shall be 230 mm. As the laying of rubble advances the soling shall be hand packed by wedging and packing with 80 mm metal in the joints of the soling and driving them by hammers in place so as to fill the voids as completely as possible. This operation of hand packing shall closely follow the rubble laying. The soling shall be laid and hand packed true to grade and section and these shall be often checked by boning rods, template boards, fish line, etc. The grades, sections, etc. of soling shall correspond to those of the surfacing coming thereon. The soling thus laid shall be finished by knocking out projecting stones and filling depressions by chips to reach up to the grade and camber The quality of the 80 mm metal shall be same as that specified for the soling stone and the longest dimension shall not be more than 100 mm and the shortest dimension not less than 50 mm.

2.1.5 Payment Measurements shall be made for the finished work in square metres of the actual plan area covered with the soling stone. The rate shall include the cost of all materials, labour, plant and equipment required in all the operations and including soling stone and gravel.

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2.2 WATERPRFOOING OF UG WATER TANK The RCC base slab & wall surface is cleaned by removing dust, dirt etc. by mechanical means. Ensure that all bolt holes and sleeves, pipe inserts have been plugged properly by using Polymer Modified Mortar (PMM). Holes are drilled for fixing of PVC nozzles at 1 mt c/c at construction joints and the same are sealed by using PMM. Further, cracks are to be opened out by making V groove and filling the same using PMM. Thereafter Injection grouting shall be done with providing and injecting nonshrink cementations grout of flowable consistency, grouting the same under pressure in pre-drilled holes by grouting pump. 24 hours after grouting is completed, cut the nipples and seal it with Polymer Modified Mortar. A layer of about 1 inch IPS in 1:2:4 is provided on the base floor with vata at wall & floor junctions providing proper slope towards the drain point. On the side walls provide double coat 20 mm thick plaster in CM 1:3 with approved waterproofing admixture followed by curing for 7 days. All mortar mix to be necessarily mixed with approved waterproofing compound. 2.3 STEEL CHEQUERED PLATES SCOPE: This specification covers general requirements for materials to be used for steel chequered plates, having raised figures at regular intervals on one surface of the plate. SUPPLY OF MATERIAL: General requirements relating to the supply of chequered plates shall conform to IS 8910. MATERIAL: Unless specified otherwise the steel (base material) for chequered plates shall conform to the requirements of Grade E 250A of IS 2062. 2.4 COLD FORMED SECTIONS Providing, supplying ,designing, detailing, fabricating and fixing erecting GI cold formed sections (GSM 120 Min), having minimum thickness of 2mm confirming to the physical specifications of ASTM A-607 (Grade 50) having minimum yield strength of 345 N/mm2 of any shape (angle, channel, zee, channel with lips, zee with lips )including fabrication drawings ( approved by Engineer) for all heights & levels including transportation of the same to site, provision of necessary erection bolts, fixing bolts, nuts, washers, cleats, and all necessary operations like straightening, cutting, drilling as specified, welding,

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cleaning, grinding and removing the welding burr etc. complete and as directed by Engineer In Charge. 2.5 SITE GRADING 2.5.1

Scope:The work covered shall consist of providing for and executing the site grading works as shown in the relevant drawings and in accordance with the specifications.

2.5.2

TECHNICAL REQUIREMENTS SETTING OUT & LEVELLING The Contractor shall be responsible for accurate and proper setting out of the work withregard to lines and levels of reference, and with regard to the correctness of dimensions, alignments and levels of the work in conformity with the drawings. The Contractor shall at his own cost, provide all necessary instruments, labour material and equipment for this purpose should any error be discovered, at any time, during the progress of work or thereafter, in the dimensions, alignment or level of part or all of work, the Contractor shall at his own expense rectify the errors to the satisfaction of the Owner/Consultant. Any checking of line or level by the Owner/Consultant shall in no way relieve the Contractor of his responsibilities. The Contractor shall, prior to start of work, construct one or more permanent bench marks at a central location from which all levels for the earth work shall be set. Permanent bench marks shall be accurately referenced to the Owner‟s plant datum. All labour and materials for setting levels shall be at Contractor‟s cost. Permanent bench marks shall be made of masonry pillars with a neatly plastered top and levelled as per the directions of Owner/Consultant. The bench marks shall be well connected with a triangular grid system or other bench marks and the entire arrangement approved by the Owner/Consultant. CLEARING AND STRIPPING The area where earth work is to be carried out shall be cleared and stripped completely of all bushes, roots, trees, shrubs and other vegetation, organic matter and other objectionable materials. All these should be completely uprooted and not merely scraped at the surface. Trees upto 50 cms girth shall be removed from the site and those above 50 cm girth shall be handed over to the Owner. Excess materials including trees, roots etc. shall be removed to the disposal areas as directed by the Owner/Consultant outside the refinery premises. EARTHWORK IN FILLING Description and Testing of Fill Material

b) The Contractor shall, at his own cost, conduct tests, to ensure the suitability of the proposed fill material. He shall submit the test results to the Owner/Consultant and obtain approval of the same before commencing the site grading operations, and, if required shall make arrangements for the Owner/Consultant to witness sample preparation and conducting of the tests. c) The Contractor shall also carry out on the proposed fill material compaction tests to determine the optimum moisture content and maximum dry density as per IS2720-Part 7:1980 and water content test as per IS 2720- Part 2:1973 to determine the natural moisture content. d) The Contractor shall repeat the tests described in 3.3.1.b and 3.3.1.c above, as often as directed by the Owner/Consultant but at least once for every 5000 m3 of fill. He shall establish an adequately equipped field laboratory for this purpose. Test results shall be carefully recorded and tagged such that when field control of moisture during the filling and compaction operation is carried out, based on them, easy and accurate identification of the test result corresponding to each stretch of fill is possible. Filling and Compaction a) The fill shall be constructed in layers, each layer being compacted to the required density before the next layer is laid. The compacted thickness shall be 200 mm for each layer. b) Compaction shall be carried out using steel wheeled or rubber tyred rollers as appropriate. The Contractor shall determine the number of passes of the roller required to achieve the required density by first conducting trials over a test stretch. Vibrating roller shall be used if it allows faster compaction. The number of passes shall be reviewed and adjusted in consultation with the Consultant/Owner, as required during the course of the work. c) All lumps and clods in the fill material shall be broken before rolling. The top surface of each layer shall be roughened before placing the subsequent layer to ensure proper keying in between layers. 39

d) Prior to rolling, the moisture content of the material shall be brought to within ± 2% of the optimum moisture content as obtained from the tests in 3.3.1.c by addition or removal of water, accompanied by thorough mixing to ensure a uniform moisture content. Each layer shall be compacted to at least 95% of the maximum dry density as obtained from the Standard Proctor Test. e) Each layer shall be tested by the Sand replacement method to ensure that the specified density has been achieved. At least one such test shall be carried out for every 2500 sq. m of graded area of every layer. If the testing indicates that any part of the fill does not meet the requirements, that part shall be reworked by the Contractor at his own cost till the specified density is achieved. f) The Contractor shall submit daily laboratory and observations report. This shall provide details of location of sample, time of collection, time it was placed in oven, the moisture content and density test results. MICROGRADING Micrograding shall be carried out by Contractor over graded areas to bring the finished grade level to level indicated, including provision of required slopes and finishes. Rolling to be done along with watering using road roller to achieve proper compaction and level. 2.6 AAC BLOCKS Scope This specification covers the construction of load bearing and non-load bearing walls with autoclaved cellular ( aerated ) concrete blocks conforming to IS : 2185 ( Part 3 ) - 1984 Mortar For Masonry The blocks shall be embedded with a mortar, the strength of which is relatively lower than that of the mix used for making blocks in order to avoid the formation of cracks. A 1:6 cement - sand mortar may be used. (Refer IS 6041-1985 Para 3, 3.9.2) Wetting of Blocks These blocks need not be wetted before or during the laying in the walls; in case the climatic condition so required, the top and the sides of the blocks may be slightly moistened. (Refer IS 6041-1985 Para 6, 6.1)

Grades The material (film) shall be classified according to the optical properties, Impact Strength and Slip. Each grade shall be designated by a set of 3 numerals. The first one will indicate optical property, the second impact strength and the third slip property. Whenever numeral '0' (Zero) is used, it shall mean the material has not been tested for that particular property. For optical properties the numeral 1 shall mean low clarity, numeral 2 normal clarity and numeral 3 high clarity. For Impact strength numeral 1 shall indicate low impact strength, numeral 2 normal impact strength and numeral 3 high impact strength. For slip property numeral 1 shall denote low slip, numeral 2 medium slip, numeral 3 high slip and numeral 4 mean extra high slip.

2.7.2

Requirements Appearance The film shall be uniform in colour, texture and finish. The material shall be substantially free from pin-holes and undispersed raw materials, streaks and particles of foreign matter. There shall be no other visible defects, such as holes, tears or blisters. The edges shall be free from nicks and cuts visible to unaided eye. The natural films shall be free from pin-holes. Film Form The film shall be furnished in the form of flat sheet or rolls or in the form of flat tubing or in any other form as agreed to between the supplier and the purchaser.

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Odour The film shall be free from any objectionable odour. Density The density of the film, when determined in accordance with A-l of IS : 2508 1984 or Method 5 of IS : 8543 ( Part l/Set 2 )-1979 shall be as prescribed in 2.1.2 and 2.2 of IS : 2508 - 1984. However, in case of dispute, the latter shall be the referee method. Melt Flow Index The melt flow index of the film when determined in accordance with 7 of IS : 2530-19637 shall be as prescribed in 2.1.2 of IS : 2508 - 1984. Black Film When tested in Bccordance with: a) 10 of IS : 2530-1963, the percentage of carbon black in material shall be 2.5 ± 0.5 percent by mass; and b) 16 of IS : 2530-1963, the dispersion of the carbon black shall be satisfactory. 2.7.3

Dimensional Requirements Nominal Thickness and Nominal Width a) Nominal thickness is the theoretically desired thickness of a film for a particular application; and b) Nominal width is the theoretically desired width of a film for a particular application. Tolerance on Thickness When tested in accordance with A-2 of IS : 2508 - 1984, tolerance on nominal thickness at any given point and the average thickness of polyethylene film for various thicknesses shall be as follows: Nominal Thickness Tolerance, Percent ± 25 Up to and including 40 m ± 20 Above 40 m Tolerance on Width The tolerance on width shall be as given below: Nominal Width mm Up to 500 Above 500 and up to 1250 Above 1250 and up to 2500 Above 2500 and up to 3000 Above 3000 and up to 7500 Above 7500 and up to 15000

Tolerance mm ±5 ±8 ± 20 ± 40 + 150, - 65 + 200, - 100 42

2.7.4

Yield Tolerance The actual yield shall be determined in accordance with the method given in A-3 of IS : 2508 - 1984, and shall be within the following tolerance limits of the nominal yield: One roll Lots of 250 kg Lots over 250 kg and up to 1250 kg Lots over 1250 kg

2.7.5

± 10 Percent ± 10 Percent ± 5 Percent ± 3 Percent

Tensile Strength at Break The tensile strength at break when tested as prescribed in A-4 of IS : 2508 - 1984, for all thicknesses of polyethylene film shall be not less than 11.77 MN/m2 (120 kgf / cm2) in lengthwise direction and 8.33 MN/m2 (25 kgf / cm2) in crosswise direction.

2.7.6

Elongation at Break The elogation at break when tested as prescribed in A-4 of IS : 2508 - 1984, for various thicknesses of polyethylene film, shall be not less than the value given below:

Thickness of the film From 12.5m up to but not including 75m 75 m and above 2.7.7

Optical Properties The 450 gloss and haze of the film, when determined in accordance with A-5 of IS : 2508 - 1984, shall conform to the requirements given below: Grade Low clarity film Normal clarity film High clarity film

2.7.8

450 Gloss Below 30 30 to 55 Greater than 55

Haze Greater than 15 percent 10 to 15 percent 6 to 10 percent

Impact Resistance The impact resistance of the film shall be as given in 4.7.1 to 4.7.3 of IS : 2508 1984.

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Low Impact Resistance Film Any LDPE film up to 40 m thickness having impact strength less than 55 gf when tested by the procedure given in A-6 of IS : 2508 - 1984 using a drop height of 66 cm would be classified as low impact resistant film. For such films, when tested in accordance with A-6 of IS : 2508 - 1984 using a drop height of 22 cm, the impact failure load shall be not less than given below for appropriate average thicknesses of the film: Average Thickness of Film m 12.5 20 25 40

Normal Impact Resistance Film When tested by the procedure given in A-6 of IS : 2508 - 1984, the impact failure load obtained from a drop height of 66 cm shall be not less than that given below against appropriate average thicknesses of the film:

High Impact Resistance Film When tested by the procedure given in A-6 of IS : 2508 - 1984, the impact failure load obtained from a drop height of 152.4 cm shall be not less than that given below against the appropriate average thicknesses of the film:

Slip The kinetic coefficient of friction for the material when tested in accordance with A-7 of IS : 2508 - 1984, shall be as follows: a) Low Slip Film b) Medium Slip Film c) High Slip Film d) Extra High Slip Film

Greater than 0.40 Greater than 0.30 and up to and including 0.40 Greater than 0.20 and up to and including 0.30 Up to and including 0.20

2.7.10 Special Requirements Heavy Duty Film LOW density polyethylene films for canal lining and other heavy duty applications like mulching, green houses, post harvest operations, construction work and allied purposes, shall have an MFI not more than 0.30 g/10 min when tested by the method given under 7 of IS : 2530-1963. The tensile strength of such films shall be not less than 140 kgf/cm2 in machine direction and 110 kgf/cm2 in transverse direction. Films shall also meet the requirement of impact strength as given in 4.7.3 of IS : 2508 - 1984. Film Having a Width of Less Than 175 mm (350 mm Slit Open Width in Case of Tubular Film) Though films of width less than 175 mm (350 mm slit open width in case of tubular films ) are not covered by this specification, if one intends to test such films, used fol general purposes or agricultural operations like nursery bags, it could be got tested only for tensile strength in machine direction and it should not be less than 120 kgf/cm2.

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2.8

LIST OF APPROVED MAKES FOR CIVIL AND ARCHITECTURAL WORKS

2.8.1

Scope a) All materials and products shall conform to the relevant standards and shall be of approved make and design. A list of manufacturers/ vendors is given in Clause 2.3.2 herein below for guidance. The Engineer shall give the approval of a manufacturer/ vendor/ only after review of the sample/ specimen. In case the same is not available in the market or in case of change in trade name, equivalent makes/ re-designated manufacturer then an equivalent approved make shall be used with the approval of Employer/ Engineer. The complete system and installation shall also be in conformity with applicable Codes & Standards and Tender specifications. b) Only “First” class quality materials shall be used. c) Employer reserves the right to choose any of the approved make / vendors as per this list. d) In case of products not indicated in this list, bis marked products shall be preferred. e) Specification of manufacturer‟s item shall be checked against tender item / specifications before selecting any product or brand name. In case of any discrepancy, tender item/ specifications shall prevail, and any such brand of item shall not be used which is not conforming to tender specifications even if it is listed in this list. f) For use of material from a bis listed/ certified manufacturer, the contractor shall furnish a copy of the valid bis certificate to eil/ Employer before procuring the material. g) In case non-availability of any item/ material among approved manufacturers/ brands at a particular site/ region, alternate manufacturers/ brands conforming to BIS/ BS etc. shall be used subject to approval by Employer. h) In case of non-availability of any manufacturer among approved manufacturers at a particular site/ region, alternate manufacturer‟s name shall be proposed along-with required credentials for Employer‟s approval. i) In case of any item/ product neither covered in this list nor having A BIS specifications, the contractor shall submit the proposed item/ product alongwith technical details/ specifications (as per bid), test certificates etc. And other credentials of the manufacturer for Employers approval.

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2.8.2 -

-

-

-

-

List of Approved Makes For Products And Materials For Civil And Architectural Works NOTE: All materials and products shall conform to the relevant standards and shall be of approved make and design. A list of manufacturers/ vendors is given separately herein below for guidance. The Engineer shall give the approval of a manufacturer/ vendor/ only after review of the sample/ specimen. In case the same is not available in the market or in case of change in trade name, equivalent makes/ re-designated manufacturer then an equivalent approved make shall be used with the approval of Employer/ Engineer. The complete system and installation shall also be in conformity with applicable Codes & Standards and Tender specifications. Only “First” class quality materials shall be used. Employer reserves the right to choose any of the approved make / vendors as per this list. In case of products not indicated in this list, bis marked products shall be preferred. Specification of manufacturer‟s item shall be checked against tender item / specifications before selecting any product or brand name. In case of any discrepancy, tender item/ specifications shall prevail, and any such brand of item shall not be used which is not conforming to tender specifications even if it is listed in this list. For use of material from a bis listed/ certified manufacturer, the contractor shall furnish a copy of the BIS certificate to Employer before procuring the material. In case non-availability of any item/ material among approved manufacturers/ brands at a particular site/ region, alternate manufacturers/ brands conforming to BIS/ BS etc. shall be used subject to approval by Employer. In case of non-availability of any manufacturer among approved manufacturers at a particular site/ region, alternate manufacturer‟s name shall be proposed alongwith required credentials for Employer‟s approval. In case of any item/ product neither covered in this list nor having A BIS specifications, the contractor shall submit the proposed item/ product along-with technical details/ specifications (as per bid), test certificates etc. And other credentials of the manufacturer for Employers approval.

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LIST OF APPROVED MAKES FOR PRODUCTS AND MATERIALS FOR CIVIL AND FINISHING WORKS ARE INDICATED IN THE TABLE BELOW. HOWEVER, ANY OTHER MAKE WHICH IS EQUIVALENT AND MEETING THE TENDER SPECIFICATIONS ARE ALSO ACCEPTABLEWITH PRIOR APPROVAL OF THE ENGINEER SR. DETAILS OF MATERIALS NO. CEMENT 1.

This specification covers the general requirements of providing and laying water mains and water supply piping, providing and fixing sanitary fixtures and piping and providing and laying drainage lines. The Work shall be carried out in accordance with the drawings and designs as would be issued to the Contractor by the Engineer duly signed and stamped by him. The Contractor shall not take cognizance of any drawings, designs, specifications, etc. not bearing Engineer's signature and stamp. Similarly the Contractor shall not take cognizance of instructions given by any other Authority except the instructions given by the Engineer in writing. The Work shall be executed and measured as per metric dimensions given in the Schedule of Quantities, drawings, etc. The Contractor shall acquaint himself fully with the partial provisions for supports that may be available in the structure and utilise them to the extent possible. In any case the Contractor shall provide all the supports regardless of provisions that have been already made. Nothing extra shall be payable for situations where bed plates (for supports) are not available or are not useful. The Contractor shall incorporate seismic considerations of anchoring and isolation in the design of the systems as per the requirements of the different equipment. Shop coats of paint that may be damaged during shipment or erection shall be cleaned off with mineral spirits, wire brushed and spot primed over the affected areas, then coated with paint to match the finish over the adjoining shop painted surface. In addition to the sectional testing carried out during the construction, the Contractor shall test the entire installation after connections to the overhead tanks or pumping system or mains. He shall rectify all leakage and shall replace all defective materials in the system. Any consequential damage done to the building, furniture and fixtures on account of Contractor‟s carelessness, like open or burst pipes or failure of fittings during testing and commissioning shall be made good by the Contractor at no additional cost.

3.2 SCAFFOLDING 3.2.1

Only steel tube scaffolding of approved design shall be used for all works. The scaffold structure shall comply with the requirements of IS: 4014 and IS: 3696. An independent tied scaffold (double scaffold), which has two lines of standards, shall be provided with the inner line kept at least one board clear of the finished face with extended transoms, or hop up baskets to carry an inside board. Diagonal braces shall not prevent the material being moved along the scaffold run. The

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scaffolding shall be suitably packed at the ends to prevent damage to the finished work. 3.3 PROTECTION 3.3.1

3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.3.7

Protection against damage: Care shall be taken to avoid damage from any cause at all stages. Packing pieces used for protection shall not disfigure or otherwise permanently mark the Works. Surface protection shall be afforded by careful handling and the avoidance of the use of hooks, crowbars, or other implements that are likely to damage the works. During installation of piping, open end of pipe shall be protected with temporary cover to prevent dust or other materials entering it. Protection during construction: Decorative surfaces shall be carefully protected during construction by providing a temporary cover. Protection of finished work: At all stages of the Contract it is essential that all works are properly protected. Suitable packing shall be used to ensure that scaffolding does not damage erected stone, marble, granite or other finished works. Any disfigurement, discolouration or imperfection whatsoever due to any reason shall not be accepted and the Contractor shall either remedy the same or redo the work at no extra cost. The decision of the Engineer as to whether any work either in whole or in part is acceptable or not shall be final and binding on the Contractor.

3.4 GUARANTEE 3.4.1

3.4.2

The Contractor shall guarantee and undertake to maintain and rectify the various components of the Plumbing work installed by him for successful performance for a period as indicated elsewhere in the tender/ contract document. The Contractor shall indemnify the Engineer for a similar period against any damage to property and injury to persons on account of any defective work or maintenance carried out by the Contractor. All sanitary wares shall be guaranteed for a period of 5 years. All CP fittings shall be guaranteed for a minimum period of 5 years.

3.5 APPLICABLE CODES, STANDARDS AND PUBLICATIONS – 3.5.1

All equipment, supply, erection, testing and commissioning shall comply with the requirements of Indian Standards and code of practices given below as amended till date. All equipment and material being supplied by the Contractor shall meet the requirements of IS and other Codes/ Publications as given below. SP: 6 (1) Structural steel sections. IS: 325 :1996 Three phase induction motors. Dimensions for pipe threads where pressure tight joints IS: 554 :1999 are required on the threads 59

PVC insulated cables for working voltages up to and including 1100 V. Specification for water meters (domestic type). Code of Practice for general construction in steel. Electroplated coatings of nickel plus chromium and copper plus nickel plus chromium. Code of Basic requirements for water supply drainage and sanitation. Technical supply conditions for threaded steel fasteners: General Requirements. Technical supply conditions for threaded steel fasteners: Tolerances for fasteners – Bolts, screws, studs and nuts – Product Grades A, B and C. PVC insulated (heavy duty) electric cables: For working voltages up to and including 1100 V. PVC insulated (heavy duty) electric cables: For working voltages from 3.3 kV up to and including 11 kV. Specification for cast iron man hole covers and frames. Code of practice for building drainage. Selection, installation and maintenance of sanitary appliances - Code of practice. Code of practice for water supply in buildings. Specification for water meters (bulk type). Colour code for identification of pipelines. Code of practice for fixing rain water gutters and down pipes for roof drainage. Recommended practice for hot dip galvanizing on iron and steel. Unplasticised PVC pipes for potable water supplies specification. Code of practice for sanitary pipe work above ground for buildings. Cast iron steps for manholes. Recommended practice for design and fabrication of material prior to galvanising. Code of practice for domestic hot water installations. Glossary of terms applicable to plumbing work. Maintenance of water supplies and fire fighting. Preformed fibrous pipe insulation. Rubber Gaskets. Code of practice for drainage of building basements. Code of practice for sanitary pipe work. Specification for design, installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages. 60

The Work shall conform to high standards of design and workmanship, shall be structurally sound and aesthetically pleasing. Quality standards prescribed shall form the backbone for the Quality Assurance and Quality Control system. At the site level the Contractor shall arrange the materials, their stacking/ storage in an appropriate manner to ensure quality. Contractor shall provide equipment and manpower to test continuously the quality of materials, assemblies, etc. as directed by the Engineer. The test shall be conducted continuously and the result of tests maintained. In addition the Contractor shall keep appropriate tools and equipment for checking alignments, levels, slopes and evenness of surface. The Engineer shall be free to carry out tests as may be considered necessary by him at his sole discretion, from time to time, in addition to those specified in this document. The Contractor shall provide the samples and labour for collecting the samples. Nothing extra shall be payable to the Contractor for samples or for the collection of the samples. The test shall be conducted at the site laboratory that may be established by Engineer or at any other Standard Laboratory selected by Engineer. The Contractor shall transport the samples to the laboratory for which nothing extra shall be payable. In the event of Contractor failing to arrange transportation of the samples in proper time Engineer shall have them transported and recover at two times the actual cost from the Contractor's bills. Testing charges shall be borne by the Contractor.

63

3.6.7

Testing may be witnessed by the Contractor or his authorised representative. Whether witnessed by the Contractor or not, the test results shall be binding on the Contractor.

All materials shall be new and of quality conforming to specifications and subject to the approval of the Engineer. Wherever particular makes are mentioned, the choice of selection shall remain with the Engineer. All appliances, fixtures and fittings shall be provided with all such accessories as are required to complete the item in working condition whether specifically mentioned or not in the Schedule of Quantities, specifications, and drawings. Accessories shall include proper fixing arrangement, brackets, nuts, bolts, washers, screws and required connection pieces. Fixing screws shall be half round head CP brass screws, with CP brass washers unless otherwise specified. Porcelain sanitary ware shall be glazed vitreous china of first quality free from warps, cracks and glazing defects conforming to IS: 2556. The choice of the colour of the Sanitary ware shall be that of the Engineer and nothing extra shall be payable to the Contractor for fixing of Sanitary ware of any colour. Sinks for Kitchen shall be of stainless steel or as specified in the Schedule of Quantities. CP fittings shall be cast brass CP of the best quality approved by the Engineer. If Supply of sanitary appliances, fixtures are fittings are in Employer‟s scope, Contractor shall ensure that no damages occur to the same during 64

h)

i)

j)

k)

l) m) n)

o) p) q) r) s)

t)

3.7.3

shifting, transportation, installation and successful handing over. If any damage occurs, the same shall be replaced by the Contractor at his own cost. All appliances, fittings and fixtures shall be fixed in a neat workmanlike manner true to level and to heights shown on the drawings and in accordance with the manufacturer‟s recommendations. Care shall be taken to fix all inlet and outlet pipes at correct positions. Faulty locations shall be made good and any damage to the finished floor, tiling, plaster, paint, insulation or terrace shall be made good by the Contractor at his own cost. All materials shall be rust proofed; materials in direct or indirect contact shall be compatible to prevent electrolytic or chemical (bimetallic) corrosion. Sanitary appliances, subject to the type of appliance and specific requirements, shall be fixed in accordance with the relevant standards and the following: Contractor shall, during the entire period of installation and afterwards protect the appliances by providing suitable cover or any other protection in order to absolutely prevent any damage to the appliances until satisfactory handing over. (The original protective wrapping shall be left in position for as long as possible). The appliance shall be placed in correct position or marked out in order that pipe work can be fixed or partially fixed first. The appliance shall be fixed in a manner such that it will facilitate subsequent removal, if necessary. All appliances shall be securely fixed. Manufacturers' brackets and fixing methods shall be used wherever possible. Compatible rust proofed fixings shall be used. Fixing shall be done in a manner that minimizes noise transmission. Appliances shall not be bedded (e.g. WC pans and pedestal units) in thick strong mortar that could crack the unit (e.g. a ceramic unit). Pipe connections shall be made with de-mountable unions. Pipe work shall not be fixed in a manner that it supports or partially supports an appliance. Appliances shall be fixed so that water falls to the outlet (e.g. baths). All appliances shall be secured as per the recommendations of manufacturer. Appliances shall be fixed true to level firmly fixed to anchor or supports provided by the manufacturer and additional anchors or supports where necessary. Sizes of Sanitary fixtures given in the Specifications or in the Schedule of Quantities are for identification with reference to the catalogues of makes considered. Dimensions of similar models of other makes may vary within +10% and the same shall be provided and no claim for extra payment shall be entertained nor shall any payment be deducted on this account.

URINAL PARTITIONS

65

a) Urinal partitions shall be Granite /white glazed vitreous china of size specified in the Schedule of Quantities. b) Porcelain partitions shall be fixed at proper heights with CP brass bolts, anchor fasteners and MS clips as recommended by the manufacturer and directed by the Engineer. 3.7.4

WASH BASIN a) Wash basins shall be white glazed vitreous china of size, shape and type specified in the Schedule of Quantities. b) Each basin shall be provided with painted MS angle or CI brackets and clips and the basin securely fixed to wall. Placing of basins over the brackets without secure fixing shall not be accepted. The MS angle shall be provided with two coats of red oxide primer and two coats of synthetic enamel paint of make, brand and colour as approved by the Engineer. c) Each basin shall be provided with 32 mm dia. CP waste with overflow, popup waste or rubber plug, CP angle valve, CP riser pipe with connectors/ adaptors and CP brass chain as specified in the Schedule of Quantities, 32 mm dia. CP brass bottle trap with CP pipe to wall flange. d) Wash basin shall be provided with hot and cold water mixing fitting or as specified in the Schedule of Quantities. e) Basins shall be fixed at proper heights as shown on drawings. If height is not specified, the rim level shall be 790 mm from finished floor level or as directed by the Engineer.

3.7.5

SINKS a) Sinks shall be stainless steel or any other material as specified in the Schedule of Quantities. b) Each sink shall be provided with painted MS or CI brackets and clips and securely fixed. Counter top sinks shall be fixed with suitable painted angle iron brackets or clips as recommended by the manufacturer. Each sink shall be provided with 40 mm dia. CP waste, CP angle valve, CP riser pipe with connectors/ adaptors and rubber plug with CP brass chain as given in the Schedule of Quantities. The MS angle shall be provided with two coats of red oxide primer and two coats of synthetic enamel paint of make, brand and colour as approved by the Engineer. c) Supply fittings for sinks shall be deck mounted CP swivel faucets with or without hot and cold water mixing fittings as specified in the Schedule of Quantities. These shall be measured and paid for separately.

3.7.6

SHOWER SET Shower set shall comprise of two CP brass concealed stop cocks, four/ five way auto-diverter, adjustable type overhead shower, all with CP wall flanges of approved quality all as specified in the Schedule of Quantities. Bath spout, shower 66

head/ rose, hand showers and pop up wastes shall also be provided wherever specified. Wall flange shall be kept clear off the finished wall. Wall flanges embedded in the finishing shall not be accepted. 3.7.7

DRINKING WATER FOUNTAIN It shall have built-in RO Filtration and UV System.Drinking water fountain shall be wall mounting type made of stainless steel or any other material as given in the Schedule of Quantities.The drinking water fountain shall be with anti-squirt bubble less, self closing valve type with automatic volume regulator.The drinking water fountain shall be provided with an anti-splash back and integral strainer with 32 mm or 40 mm cast brass trap.

3.7.8

3.7.9

MEASUREMENT AND RATES Sanitary fixtures (Porcelain ware and CP fittings) shall be measured by numbers. Rate for providing and fixing of sanitary fixtures, accessories, shall include all items, and operations stated in the respective specifications and Schedule of Quantities and nothing extra is payable. Rates for all items under specification Clauses above shall be inclusive of cutting holes and chases and making good the same, CP brass screws, nuts, bolts and any other fixing arrangements required and recommended by manufacturers, testing and commissioning etc. complete. Toilet Paper Holder Toilet paper holder shall be white glazed vitreous china or chrome plated of size, shape and type specified in the Schedule of Quantities. Porcelain toilet paper holder shall be fixed in walls and set in cement mortar 1:2 (1 cement : 2 coarse sand) and fixed in relation to the tiling work. The latter (chrome) shall be fixed by means of screws/capping having finish similar to the toilet paper holder in wall/temper partitions with raw l plugs or nylon sleeves. When fixed on timber partition, it shall be fixed on a solid wooden base member provided by the Owner‟s Site Representative.

3.7.10 P.V.C Connectors These shall be of specified size, of appropriate length with brass unions and wiped solder joint, shall be bent to correct shape without any distortions, and work shall include all the operations, such as fixing, as necessary for satisfactory working of the same. 3.7.11 TOILETS FOR THE DISABLED Where specified, in washroom facilities designed to accommodate physically disabled, accessories shall be provided as directed by the Owner‟s Site Representative.

67

Stainless steel garb brass of required size suitable for concealed or exposed mounting and opened non-slip gripping surface shall be provided in all washroom. The flushing cistern/valve shall be provided with chromium plated long handles. 3.7.12 MOCKUP AND TRIAL ASSEMBLY The installation of the sanitary fixtures and fittings shall be as per the shop drawings approved by the Architect/Consultant. Contractor has to make sure the availability of every fixture to be displayed in the mock-up. Mock-up shall present the exact presentation which is going to be finalised for the installation. Only after the approval of the client and architect, contractor shall consider it as a benchmark and follow the same procedure to do the rest of the installation. Owners Site representative shall make sure contractor follows the same and maintains the quality. Relevant instructions from manufacturers shall be followed as applicable. This trial assembly shall be developed to determine the location of puncture holes, holding devices etc. which will be required for final installation of all sanitary fixtures and fittings. The above assembly shall be subject to final approval by the Architect / Interior Designer. The fixtures in the trial assembly can be re-used for final installation without any additional payments for fixing or dismantling of the fixtures 3.8 SOIL, WASTE, VENT AND RAINWATER PIPES 3.8.1

SCOPE OF WORK a) Soil, waste, vent and rain water disposal scope shall include Supply, Installation, testing, commissioning and successful handing over to Employer as per the drawings, specifications and Schedule of Quantities. b) All soil, waste and storm water disposal for the portion above ground level to the public sewers shall be by gravity, whereas from the basement it shall be by pumping. Without restricting to the generality of the foregoing, the soil, waste, vent and rain water pipes system shall inter-alia include the following: c) Vertical and horizontal soil, waste, vent and rainwater pipes and fittings, joints, supports, paints and connections to fixtures. d) Connection of all pipes to sewer lines as shown on the drawings at ground level. e) Floor and urinal traps, clean out plugs, inlet fittings and rainwater (roof) outlets. f) Testing of all pipes and fittings in the workshop. g) Testing, commissioning and handing over of all pipes lines after installation.

3.8.2

GENERAL REQUIREMENTS

68

a) Pipes and fittings shall be fixed truly vertical, horizontal or in slopes as required in a neat workmanlike manner. b) Pipes shall be fixed in a manner so as to provide easy accessibility for repair and maintenance and shall not cause obstruction in shafts, passages etc. c) Pipes shall be securely fixed to walls and ceilings by suitable clamps at intervals specified. Only approved type of anchor fasteners shall be used for fixing pipes on RCC ceilings and RCC/ masonry walls. d) Access doors for fittings and clean outs shall be so located that they are easily accessible for repair and maintenance. e) Long bends shall be used on all main pipelines as far as possible. Use of elbows shall be restricted for short connections. f) Wherever piping is going across the separation/ expansion joints of buildings, piping shall be provided with flexible connectors on both sides of such joints or on single side depending on whether any wall is to be crossed or not. 3.8.3

UPVC PIPE WORK UPVC SWR(Soil Waster and Rain water ) pipe work shall be provided for above ground soil, waste, vent and rain water pipe work as shown in drawings. UPVC SWR pipes and fittings shall confirm to IS: 13592 and IS: 14735 respectively. Pipes shall be of Type - B, pressure rating 6 kg/cm2. The pipes shall be supplied in nominal lengths of 2, 3, 4 or 6 metres, tolerance on specified lengths shall be +10 mm and -0 mm. Any physical test requirements shall be as per IS: 13592 1992.

3.8.4

Handling Because of their light weight, there may be a tendency for the UPVC pipes to be thrown often during installation. Reasonable care should be taken in handling and storage to prevent damage to the pipes. The pipes shall be stored as per manufacturer‟s recommendation. The Contractor shall be fully responsible in this case. In no case, pipes should be dragged on the ground. Pipes should be given adequate supports at all times.

3.8.5

Pipe Work Installation a) UPVC pipes shall be laid under the flooring or hanging below slab or fixed on walls either buried or exposed as the case may be, as shown in the drawings. The minimum thickness of fittings shall be of 3.2 mm. the fittings shall be of injection mould type with solvent cement joint (for exposed piping) or rubber ring joint (for concealed piping). The pipes and fittings shall be capable of withstanding sun‟s rays. UPVC pipes laid below slab or suspended from ceiling shall be supported by GI angle brackets/ supports as detailed in the drawings. 69

b) All vertical pipes shall be fixed by GI clamps truly horizontal. Branch pipes shall be connected to the stack at the same angle as that of the fittings. No collars shall be used on vertical stacks. Each stack shall be terminated at top with a vent cowl (terminal guard). c) Horizontal pipes running along ceiling shall be fixed on structural members by adjustable clamps of special design shown on the drawings or as directed. Horizontal pipes shall be laid to uniform slope and the clamps adjusted to the proper levels so that the pipes fully rest on them. d) Contractor shall provide all sleeves, openings, hangers and anchor fasteners during the construction. Sleeves shall be one size higher then pipe or there should be at least 12 mm gap all around between pipes and sleeves. Wherever pipe passes through fire rated wall, the gap shall be filled with fire rated sealant as directed by Engineer. For non-fire rated wall, gap shall be filled with wool and silicon sealant (20 mm depth). Contractor shall provide all necessary information to the building work Contractor for making such provisions in the structure as necessary. All damages shall be made good by the Contractor at his own cost to restore the surface. e) Door type fittings shall be used in vertical piping installations. Door position of fittings shall be on top of fitting. Easy removal of access door should be possible. The access door shall be air and water tight. Single yee shall be used for horizontal branch connection. Double - yee fittings shall be used in vertical piping branch connection only. 3.8.6

Jointing a) UPVC pipes and fittings shall be joined as per the manufacturer‟s instructions/ recommendations. UPVC pipes and fittings shall be joined with Solvent Cement and jointing shall be carried out as follows: b) Cut the spigot end of the pipe square. c) All burrs from the internal and external surfaces should be removed. d) The spigot should be marked with a pencil line at a distance equivalent to the socket depth. Clean the surface within the marked area. e) Apply uniform coat of approved solvent cement on the external surface to the pipe and a lighter coat on the internal surface of the fitting. f) Insert the pipe end into the socket of the fitting and push it in upto the mark. g) The pipe work should be assembled in a manner such that it does not entail making of joints in restricted area. h) UPVC Pipe Work Testing i) UPVC pipes and fittings assembled shall be tested in accordance with IS 13592 - 1992. The openings of the pipes shall be sealed for the section to be tested. The water column of 2 m shall be maintained for a maximum of 15 minutes. Contractor with his team shall examine carefully all the joints for leakage.

70

j) The Contractor shall test all vent pipes by a smoke testing machine. Smoke shall be pumped into the stack after plugging all inlets and connections and filling water in all trap seals. The test shall be conducted under a pressure of 25 mm of water and shall be maintained for 15 minutes. The stack shall then be observed for leakages and all defective pipes and fittings removed or repaired as directed by the Engineer. k) A test register shall be maintained and all entries signed and dated by Contractor and Engineer. A proforma of the proposed test register shall be submitted to the Engineer for approval. l) All pipes in wall chase or meant to be encased or buried shall be hydro tested before the chase is plastered or the pipe encased or buried. m) All systems shall be tested in sections as required to expedite the work for other trades and meet construction schedules and final test on completion. 3.8.7

WASTE PIPE FROM APPLIANCES Waste pipe from appliances e.g. washbasins, baths, sinks and urinals, etc. shall be of UPVC confirming IS: 4985 as given in the Schedule of Quantities. The internal diameter sizes of outlet branch waste pipes for different fittings shall be as follows: Wash Basin 40 dia. Urinals 50 dia. Sink 50 dia. Nahani Trap 75 dia., 50 mm seal. 75 or 100 dia. as required, with 50 Multi Floor Trap mm or 75 mm seal. Wash troughs 50 dia. Canteen wash areas 50 dia. All pipes shall be fixed in gradient towards the outfalls of drains. Pipes inside a toilet room shall be in chase unless otherwise shown on drawings. Where required pipes may be run at ceiling level in suitable gradient and supported on structural clamps as directed by the Engineer. Spacing for the clamps shall be 3,000 mm for vertical runs and 2,400 mm for horizontal runs. Pipes shall be UPVC tubes conforming to IS: 4985 and quality certificates shall be furnished. Pipes shall be provided with all required fittings conforming to IS: 4985 e.g. tees, couplings, bends, elbows, unions, reducers, nipples, plugs, etc. All UPVC waste pipes shall be terminated at the point of connection with the appliance with an outlet of suitable diameter. Pipes shall be painted as specified under Clause Error! Reference source not found..

RAINWATER PIPES All rainwater pipes shall be of UPVC/ HDPE as shown in drawing and specified in specification. UPVC piping shall conform to IS: 4985 and 6 kg/cm2 minimum pressure rating or as specified in the Schedule of Quantities.

3.9.5

RAIN WATER OUTLET a)

b)

Rain water outlet shall be preferably scupper type drain with cast iron body and cast aluminium grating with stainless steel screws. Suitable adapter/ connector shall be used to match the pipe. Wherever shafts are not available near rain water outlet, dome type rain water outlet shall be installed. Rain water outlet shall be tested for water leaking, prior to waterproofing treatment. Extreme care shall be taken, while sealing gap between rain water outlet and wall/ slab.

3.10 MEASUREMENT AND RATES 3.10.1

General a) Rates for all items shall be inclusive of all work and items called for in the specifications given above and the Schedule of Quantities as applicable for the work under floors, in shafts or at ceiling level at all heights and depths. b) All rates are inclusive of cutting holes and chases in RCC and masonry work and making good the same.

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c)

All rates are inclusive of shop testing, pre-testing at site and final testing of the installations, materials and commissioning.

3.10.2 Pipes a) b)

c)

The unit of measurement shall be linear metre to the nearest centimetre. All CI/ UPVC/ HDPE soil, waste, vent, anti-siphonage and rain water pipes shall be measured net, correct to a centimetre, including all fittings along their length after fixing. The length shall be taken along centre line of the pipes and fittings. No allowance shall be made for the portions of pipe lengths entering the sockets of the adjacent pipes or fittings. The above shall apply to all cases i.e. whether pipes are fixed on wall face or pillars or embedded in masonry or pipes running at ceiling level. The quoted rate shall include lead jointing. All CI/ UPVC/ HDPE pipes shall be measured in running metre correct to a centimetre for the finished work which shall include fittings e.g. bends, tees, elbows, reducers, crosses, sockets, nipples, nuts, unions, etc. The length shall be taken along centre line of the pipes and fittings. All pipes and fittings shall be classified according to their diameter, method of jointing and fixing substance, quality and finish. The diameters shall be nominal diameter of internal bore. In case of fittings of unequal bore, the largest bore shall be considered.

3.10.4 Traps Unit of measurement shall be the number of pieces. All urinal traps, trap gratings, hoppers, clean out plugs shall be measured by number and shall include all items described in the relevant specifications and Schedule of Quantities. Cockroach

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traps shall not be measured separately and are deemed to be included in the rate for Traps. 3.10.5 Painting Painting of pipes shall be measured per running metre for each diameter of pipe and shall be inclusive of all fittings and clamps. No deduction shall be made for fittings. 3.10.6 Excavation for Soil Pipes No extra payment shall be admissible for excavation, dewatering, back filling, consolidation and disposal of surplus earth for soil and waste pipes. 3.10.7 Rain Water Outlet Rain water outlet shall be measured by numbers for different sizes. Leaf and gravel grates along with the perforated ring shall be measured in kilograms. 3.11 WATER SUPPLY SYSTEM 3.11.1 SCOPE OF WORK a)

b) c) d) e) f) g) h)

The scope shall include supply, installation, testing, commissioning and satisfactory handing over of the complete water supply system to Employer as per drawings, specifications and Schedule of Quantities. The water supply system shall include the following: Distribution system from main supply or overhead tank to all fixtures and appliances for cold and hot water. Insulation for hot water pipes. Pipe painting. Control valves, masonry chambers and other appurtenances. Connections to all plumbing fixtures, tanks, appliances. Inserts, nozzles for Reinforced Concrete tanks. The term water supply is used as indicative of all water supply work required and necessary for the building including such external work as may be necessary to make the system functional.

3.11.2 GENERAL REQUIREMENTS If necessary and if approved by the Engineer, where unavoidable, bends may be formed by means of a hydraulic pipe bending machine for pipes up to 20 mm dia. No bending shall be done for pipes of 25 mm dia. and above. After bending zinc rich paint shall be applied wherever the zinc coating is damaged. Valves and other appurtenances shall be so located as to provide easy accessibility for operations, maintenance and repairs. Valves shall be located at a height not 74

exceeding 1.6 m above their operating floor/ platform level. Where such a provision is not possible and the valve is to be frequently operated a MS chain shall be provided for its operation. 3.11.3 GI PIPES, FITTINGS AND VALVES a)

b)

c)

All pipes inside the buildings and where specified, outside the building shall be MS galvanised steel tubes conforming to IS: 1239 of Class specified. When Class is not specified they shall be Heavy Class. All embedded/ concealed pipes shall be of heavy duty. Fittings shall be of malleable cast iron galvanised, of approved make. Each fitting shall have manufacturer's trade mark stamped on it. Fittings for GI pipes shall include couplings, bends, tees, reducers, nipples, unions, bushes, etc. Fittings, etc. shall conform to IS: 1879. Pipes and fittings shall be jointed with screwed joints using Teflon tape suitable for water pipes. Care shall be taken to remove burr from the end of the pipe after cutting by a round file. All pipes shall be fixed in accordance with layout and alignment shown on the drawings. Care shall be taken to avoid air pockets. Necessary vents and drains shall be provided at all high and low points respectively. GI pipes inside toilets shall be fixed in wall chases well above the floor. No pipes shall be run inside a sunken floor as far as possible. Pipes may be run under the ceiling or floors and other areas as shown on drawings. All pipe joints after testing of the line shall be seal welded and the weld plus the adjoining portion shall be given two coats of zinc rich primer.

3.11.4 Clamps GI pipes in shafts and other locations shall be supported by GI clamps of design approved by the Engineer. Pipes in wall chases shall be anchored by iron hooks. Pipes at ceiling level shall be supported on structural clamps fabricated from MS structural sections. Pipes in shafts shall be supported on slotted angles/ channels as specified/ as directed. 3.11.5 Unions Contractor shall provide adequate number of unions on all pipes to enable easy dismantling later when required. Unions shall be provided near each gunmetal valve, stop cock or check valve and on straight runs as necessary at appropriate locations as required for easy dismantling and/ or as directed by the Engineer. 3.11.6 Flanges Flanged connections shall be provided on pipes as required for maintenance/ ease in dismantling or where shown on the drawings, all equipment connections as necessary and required or as directed by the Engineer. Connections shall be made 75

by the correct number and size of the GI nuts/ bolts as per relevant IS Standards and made with 3mm thick insertion rubber washer/ gasket. Where hot water or steam connections are made insertion gasket shall be of suitable high temperature grade and quality approved by the Engineer. Bolt hole dia. for flanges shall conform to match the specification for CI sluice valve as per IS: 780. Gaskets shall conform to IS: 11149. 3.11.7 Trenches All GI pipes below ground shall be laid in trenches with a minimum cover of 600 mm. The width and depth of the trenches shall be as follows except at places where welding/ jointing, etc. needs larger width of trench. Additional width/ depth shall be provided as necessary for welding/ jointing, etc. at no additional cost: 3.11.9 Width of 3.11.10 Depth of 3.11.8 Diameter of trench trench pipe (mm) (mm) (mm) 3.11.11 15 to 50 3.11.12 300 3.11.13 750mm 3.11.14 65 to 100 3.11.17 Sand Filling

3.11.15 450

3.11.16 1000mm

GI pipes in trenches shall be protected with fine sand 150mm all around before filling in the trenches. 3.11.18 Painting All pipes above ground shall be painted with one coat of red lead and two coats of synthetic enamel paint of approved shade and quality to give an even shade, or as specified by the Engineer. 3.11.19 Hot water pipes in chase: All hot water pipes fixed in wall chase shall be properly insulated by elastomeric tape as per manufacturer‟s recommendation. 3.11.20 Pipe Protection Where specified, pipes below floor or below ground shall be protected against corrosion by the application of two or more coats of solvent based rubberised asphaltic primer to give a uniform coat covered with two layers of 2 mm thick bituminous based anti-corrosive tape. The application of primer and anti-corrosive tape shall be done as specified by the manufacturer. 3.11.21 Reverse Osmosis Unit

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Supplying & fixing potable Reverse Osmosis Unit (RO Unit) includes with ultra filtration & ultra violet treatment, shall have purified water flow rate of 15 litres/ hour, and 7 litres water storage capacity suitable for all kind of raw water. RO unit shall be suitable for minimum 90 % of TDS reduction & minimum 25 % water recovery. RO unit shall consist of all accessories, valves, fittings etc required for complete satisfactory installations as required by client / engineer-incharge. 3.11.22 Drinking Water Cooler Unit Supplying & fixing two tap stainless steel storage type drinking water cooler, which includes ultra filtration shall have 100 litres storage capacity and 100 litres/hour water cooling capacity. Water cooler unit shall have adjustable cold water thermostat, overload compressor protection and mechanically expanded compressor. Water cooler unit shall consist of all accessories, valves, fittings etc required for complete satisfactory installations as required by client / engineer-incharge. 3.12 VALVES & FITTINGS 3.12.1 Gunmetal Valves Valves 50 mm dia. and below shall be heavy gunmetal full way valves or globe valves conforming to Class I of IS: 778. Valves shall be tested at manufacturer's works and the same stamped on it.All valves shall be approved by the Engineerin-Charge before they are allowed to be used in the Work. 3.12.2 Sluice Valves Unless otherwise specified all valves 80 mm dia. and above shall be CI double flanged sluice valves with non rising spindle. Sluice valves shall be provided with wheel when they are in exposed positions and with a cap top when they are located underground. Contractor shall provide suitable operating keys for sluice valves with cap tops.Sluice valves shall be of approved makes conforming to IS: 780 of Class as specified 3.12.3 Butterfly Valves a)

b) c)

Where specified, Valves 65mm dia. and above shall be cast iron butterfly valve to be used for isolation and/ or flow regulation as directed by the Engineer. The valves shall be tight shutoff/ regulatory type with resilient seat suitable for flow in either direction and seal in both directions. The butterfly valve shall be suitable for waterworks and rated Pressure requirement as mentioned in the Schedule of quantities. The body shall be of cast iron to IS:210 in circular shape and of high strength to take the water pressure. The disc shall be heavy duty cast iron with anti corrosive epoxy or nickel coating. 77

d)

e)

f)

The valve seat shall be of high grade elastomer or nitrile rubber. The valve is closed position shall have complete contact between the seat and the disc throughout the perimeter. The elastomer rubber shall have a long life and shall not give away on continuous applied water pressure. The shaft shall be EN 8 grade carbon steel. The valve shall be fitted between two flanges on either side of pipe flanges. The valve edge rubber shall be projected outside such that they are wedged within the pipe flanges to prevent leakages. Butterfly valve shall conform to IS: 13095.

3.12.4 Non Return Valve Where specified non return valve (swing check type) shall be provided through which flow can occur in one direction only. It shall be single door swing check type of best quality conforming to IS: 5312. 3.12.5 Forged Brass Ball Valve Valves of size 50 mm dia. and below shall be full bore quarter turn lever operated female threaded forged brass hard chrome plated ball valves conforming to IS: 554. Valve shall have PTFE body seat rings and gland packing, forged brass ball, stem and bonnet, carbon steel nut washer and lever and finished in chrome. Valves shall have minimum working pressure of 16 bar. Valves shall be tested at manufacturer's works and the same stamped on it. 3.12.6 Ball Type Non Return Valve (NRV) Ball type NRV shall be used in water treatment plants and sewage sump pump piping. NRV shall be constructed in cast iron body with epoxy coating, phenolic resin and NBR (Nitrile) seal. NRV shall have flanged ends and can be installed in horizontal as well as vertical position. NRV shall have minimum working pressure of 10 bar or as per system requirements. Valves shall be tested at manufacturer's works and the same stamped on it. 3.12.7 Air Release Valve (ARV) Pressurised water supply lines shall be provided with air release valve at highest point to release accumulated air for piping system. Air release valve shall be automatic float operated; the diameter shall be as specified in the Schedule of Quantities. Air release valve shall be provided with ball valve for ease in Operation and Maintenance. Valve body shall be in cast iron stainless steel, brass and EPDM internal components. Valves shall have minimum working pressure of 10 Kgs. 3.12.8 Ball float valve Ball valves with floats to be fixed in storage tanks shall consist of cast brass lever arm having copper balls (26 SWG) screwed to the arm integrally. The copper ball 78

shall have bronze welded seams. The closing/opening mechanism incorporating the piston and cylinder shall be non-corrosive metal and include washers. The size and construction of ball valves and float shall be suitable for desired working pressure operating the supply system. Where called for brass valves shall be supplied with brass hexagonal back nuts to secure them to the tanks and a socket to connect to supply pipe. These valves are required to maintain a constant level in service reservoirs and steel storage tanks. These shall be available for static pressure of 7 Kg/cm2 flanges faced and drilled to BS 10, table C, tested to 250 pounds per square inch. These shall conform to BS-1212 Part-2 and IS 1703 3.13 TESTING 3.13.1 All pipes, fittings and valves shall be tested in accordance with IS: 2065 except as may be modified herein under. All pipes, fittings and valves, after fixing at site, shall be tested to a hydrostatic pressure of 10 kg/cm2 or 1.5 times the shut off head of the pump whichever is greater. 3.13.2 The test pressure shall be maintained for a period of at least thirty minutes without any drop in pressure. 3.13.3 A test register shall be maintained and all entries shall be signed and dated by Contractor(s) and the Engineer. 3.13.4 After commissioning of the Water Supply System, the Contractor shall test each valve by closing and opening it a number of times to observe if it is working efficiently and effectively. Valves which do not operate efficiently and effectively shall be replaced by new ones at no extra cost and the same shall be tested as above. 3.13.5 All pipes in wall chase or meant to be encased or buried shall be hydro tested before the chase is plastered or the pipe encased or buried. 3.13.6 INSULATION a) b) c) d) e)

All surfaces shall be thoroughly cleaned with a wire brush. One layer of approved primer shall be applied and premoulded pipe insulation sections shall be fixed. 79

c) d) e)

One layer of aluminium foil of thickness 0.711 mm (20 SWG), shall be applied as a finish layer. Insulation for hot water pipes in chase: All hot water pipes in chase shall be insulated with 3 mm elastomeric tape as per manufacturer‟s recommendations.

3.13.8 DISINFECTION OF INSTALLATION a) b) c) d) e) f) g)

h)

The water supply installation shall be disinfected as per standards and as follows: Tanks and pipes shall be filled and flushed out. All bib cocks (taps) shall be closed. Tanks and pipes shall be re-filled while adding a sterilising admixture containing 50 parts chlorine to one million parts water. When the installation is filled all bib cocks (taps) shall be opened progressively and each allowed to run until the water smells of chlorine. The installation shall be topped up and more steriliser added. The installation shall then be left for three hours and shall then be tested for residual chlorine; if none is found, the installation shall be drained and the process repeated. The installation shall be finally drained and flushed with potable water before use.

3.13.9 MEASUREMENT AND RATES 3.13.9.1 GI and CPVC Pipes a) GI pipes above ground shall be measured per linear metre (to the nearest cm) along the centre line of the pipe and shall be inclusive of all fittings e.g. couplings, tees, bends, elbows, unions, flanges, etc. Deduction for valves shall be made. Rates quoted shall be inclusive of all fittings, clamps, cutting holes chases and making good the same and all other items mentioned in the specifications and Schedule of Quantities. b) GI pipes below ground shall be measured per linear metre (to the nearest cm) along the centre line of the pipe and shall be inclusive of all fittings e.g. couplings, tees, bends, elbows, unions and flanges, etc. Deduction for valves shall be made. Rates quoted shall be inclusive of all fittings, cutting holes and chases and making good the same and all other items mentioned in the specifications and Schedule of Quantities. Excavation, filling, back filling with selected excavated earth, compaction and disposal of surplus earth, fine sand filling around GI pipes, in external work shall be measured separately, as per respective items. 3.13.10 VALVES, BIB COCKS AND STOP COCKS a) Gunmetal and cast iron valves, Bib cocks and stop cocks shall be measured by numbers. b) Flanges for Nozzles 80

c) d) e)

Flanges for nozzles shall be measured by numbers and the quoted rate shall include welding of the flanges to the pipe nozzles. Painting/ Pipe Protection/ Insulation Unless otherwise specified painting/ pipe protection/ insulation for pipes shall be measured and paid for separately. These shall be measured per linear metre along the centre line of the pipe, over the finished surface and shall include all valves and fittings for which no deduction shall be made.

3.13.11 Pressure Reducing Valve Set a)

Each pressure reducing valve set shall be complete with pressure reducing or pressure regulating valve, isolating valves, pressure gauges (fix with symphonic check) on inlet and outlet, pressure relief valve on outlet and filter on inlet. b) Each pressure reducing valve shall contain loading neoprene diaphragm and a full floating, self aligning, ignition resistant seat and shall be of the single stage, pressure reduction type with provision for manually adjusting the delivery pressure. The valve shall fail safe to the low pressure. c) Valves shall be capable of operating at the maintaining automatically the respective delivery pressure and flow rates as indicated and shall not be liable to creep. Valves shall also be capable of maintaining the pre-set down stream pressure under static condition. d) The filter on each inlet to a pressure reducing valve shall be of replaceable porous sintered metal type. 3.13.12 Water Meters. a) Water meter shall communicate with DDC or PLC through open communication protocol such as RS-485, MODBUS, BACnet etc. Plumbing Contractor shall co-ordianate with IBMS contractor for the connection purpose b) Water meters of approved make and design shall be supplied for installation at locations as shown. c) The water meters shall meet with the approval of local supply authorities. Suitable valves and chambers or wall meter box to house the meters shall also the be provided along with the meters. d)

The meters shall conform to Indian Standard IS:779 and IS:2373. Calibration certificate shall be obtained and submitted for each water meter.

e)

Provision shall also be made to lock the water meter. The provision shall be such that the lock is conveniently operated from the top. Where the provision is designed for use in conjunction with padlocks, the hole provided for padlocks shall be a diameter notlessthan4mm.

f)

The G.I. lines shall be cut to the required lengths at the position where the meter and stop cock are required to be fixed. Suitable fittings shall be 81

attached to the pipes. The meter and stop cock shall be fixed in a position by means of connecting pipes, jam nut and socket etc. g)

The stop cock shall be fixed near the inlet of the water meter. The paper disc inserted in the ripples of the meter shall be removed. And the meter installed exactly horizontal or vertical in the flow line in the direction shown by the arrow cast on the body of the meter. 15.8 Care shall be taken that the factory seal of the meter is not disturbed. Wherever the meter shall be fixed to a newly fitted pipe line, the pipe line shall have to be completely washed before fitting the meter.

3.13.13 Expansion Bellow a)

b) c)

Rubber expansion joint with unit control (tie rod & gusset plate) shall be as per manufacturers specifications of standard length complete with all accessories tested to a pressure not less than 15 Kg./sqcm including rubber gaskets, flanges, nuts, bolts & washers complete as required. Pressure Gauge The pressure gauge shall be constructed of die cast aluminium and stove enamelled. It shall be weather proof with an IP 55 enclosure. It shall be a stainless steel Bourden tube type pressure gauge with a scale range from 0 to 16 Kg / cm square and shall be constructed as per IS:3524. Each pressure gauge shall have a siphon tube connection. The shut off arrangement shall be by Ball Valve. Calibration certificate shall be obtained and submitted for each pressure gauge

3.14 DRAINAGE 3.14.1 SCOPE OF WORK a)

b) c)

d)

The scope shall include supply, installation, testing, commissioning and satisfactory handing over of the complete drainage system to client as per drawings, specifications and schedule of quantities. Without restricting to the generality of the foregoing, the drainage system shall inter-alia include: Sewer lines including earthwork for excavation, disposal, backfilling and compaction, pipelines, manholes, drop connections and connections to the municipal or existing sewer. Storm water drainage, earth works for excavation, disposal, backfilling and compaction, pipe lines, manholes, catch basins and connections to the existing municipal storm water drain or connected as indicated by the Engineer.

3.14.2 GENERAL REQUIREMENTS

82

a) b) c) d)

Drainage lines and open drains shall be laid to the required gradients and profiles. All drainage work shall be done in accordance with the Local municipal bye-laws. Contractor shall obtain necessary approval and permission for the drainage system from the municipal or any other competent Authority. Location of all manholes, etc. shall be got confirmed by the Engineer-inCharge before the actual execution of work at site. As far as possible, no drains or sewers shall be laid in the middle of road unless otherwise specifically shown on the drawings or directed by the Engineer-in-Charge in writing.

3.14.3 GULLY TRAPS Gully traps shall be of the same quality as described for stoneware pipes. Gully traps shall be fixed in a masonry chamber as per specifications. The CI sealed cover and frame shall weigh not less than 7.3 kg. Where necessary, sealed cover shall be replaced with CI grating of the same size. Rubber rings shall conform to IS: 5382. Gully traps shall be measured by the number and rate shall include all excavation, back filling, foundation, concrete brick masonry, cement plaster inside and outside, CI grating and sealed cover and frame, etc. complete. 3.14.4 CAST IRON PIPES Cast iron pipes and fittings shall be of good and tough quality and dark grey on fracture. The pipes and fittings shall be true to shape, smooth and cylindrical, their inner and outer surface being as nearly as practicable concentric. They shall be sound and nicely cast, shall be free from cracks, taps, pinholes and other manufacturing defects. The pipes and fittings shall conform to IS:3989 / IS:1729 as called for. Fittings shall be of required degree with or without access door. All access doors shall be made up with 3mm thick insertion rubber gasket of white lead and tightly bolted to make the fittings air and water tight. The fittings shall be of the same manufacture as the pipes used for soil and waste. All CI pipes and fittings shall bear the manufacturer's name and ISI specification to which it conforms. All pipes and fittings shall be coated internally and externally with the same material at the factory, the fittings being preheated prior to total immersion in a bath containing a uniformly heated composition having a tar/other suitable base. The coating material shall have good adherence and shall not scale off. The coating shall be smooth and tenacious and hard enough not to flow when exposed to a temperature of 77 degree C but not so brittle at a temperature of '0' degree C as to chip off when scratched lightly with a pen knife.

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All pipes and fittings before installation at site shall be tested hydrostatically to a pressure of 0.45 Kg/sq. cm without showing any sign of leakage, sweating or other defects of any kind. The pressure shall be applied internally and shall be maintained for not less than 15 minutes. All these tests shall be carried out in the presence of the representative of the Project Manager. Alternatively a test certificate from manufacturers be obtained before dispatch of material to site. Cast Iron Specialities If required, Cast iron speciality items such as deep seal floor traps, urinal traps, trap integral pieces with integral inlet/outlet connections, manhole cover with frame, chamber cover etc. shall be fabricated to suit individual location requirements. The contractor shall arrange the fabrication of these items from an approved source. Lead Caulked joints with pig lead: The approximate depth and weights of pig lead for various diameters of CI pipes and specials shall be as follows: Nominal size of Pipe (mm) 50 80 100 150

Lead per Joint (Kg) 0.77 0.88 0.99 1.5

Depth of Lead Joint (mm) 25 25 25 38

Pipe Joint Sealant: Pipe joint sealant shall be used for joining various diameters of C.I. pipes and specials. This sealant replaces the standard lead caulked joints. The application is by Homogenously mixing the two pack system in cold condition. Application Procedure: Clean the pipe joints thoroughly to ensure it is free from any traces of oil, dirt or any other foreign body. Mix two parts of Drip Seal thoroughly with an iron flat to get a homogenous compound. * Place Spun yarn in the pipe joint as a filler and then take the required quantity of the compound and push it in the joint with a caulking tool, MS flat / damp finger uniformly all over to obtain a smooth and uniform joint. Dip the fingers in water every often to ensure the compound does not stick to the hands of the workmen, but this will ensure perfect sealing and the smooth surface for the joint cement. (* The compound prepared from the two mixtures is to be used within 30 minutes) Precaution to be taken to wash hands thoroughly with soap before and after use. Preferably use disposable gloves for hand application.

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3.15 PUMPS 3.15.1

Inline Pumps a) Pumps shall be suitable for single as well as parallel efficient operation at any point in between the maximum and minimum system resistances. b) Pumps shall run smooth without undue noise and vibration, cavitations, oil or water leaks over the range of operation. To ensure vibration free operation, all rotating components of pump shall be statically and dynamically balanced to BS 6861/ as per zones A & B of ISO 10816 -1 c) The pump set shall be suitable for starting with discharge valve open and/or closed. d) The pump set shall be capable of withstanding the accidental rotation in reverse direction. e) Pumps shall be so selected that the design duty point is within 5% of the maximum efficiency point. f) The pump casing shall have ample space to take an impeller one size larger than that capable of performing the design duty. g) The pump shall have a speed of not more than 1500 rpm. The pump shall be lubricated in strict accordance with the manufacturer`s instructions and shall be factory aligned prior to shipment. h) Facilities to select which pump to be duty pump and standby pump shall be provided and shall be interchangeable. Leakage from pump gland shall be drained to the nearest floor waste.

3.15.2 . a)

b)

c)

d)

e) f)

Features of construction Pump shall be Vertical, centrifugal, with enclosed, radial impeller. Impeller shall be hydraulically balanced and keyed to shaft. The impeller shall have superior suction eye design to ensure the lower NPSH. Pump casing shall be of robust construction. Liquid passages shall be finished smooth and designed as to allow smooth flow. The volute tongue shall be filed to a smooth rounded edge. The vertical shaft shall be of high tensile stainless steel supported by bush bearings shall. The shaft shall be sealed with mechanical seal of DIN 24960 standard. The bearing shall be radial type bush bearing of tungsten carbide on shaft and ceramic bearing in the diffuser. The bearing shall be self lubricated and highly wear resistant. The motor bearing shall be capable of withstanding the axial thrust. Bearings shall be capable of taking the static weight of the rotating parts and any thrust generated by the operation of the pump. The bearing life shall be minimum 40,000 hrs of operation. The diffusers shall be made with pressed stainless steel and shall be designed to reduce the internal losses. Each pump shall be provided with an automatic coupling device for attaching the crane hook to the pump at low level, this automatic coupling 85

Material test certificates from Government approved metallurgical laboratory shall be furnished by the Contractor Each pump shall be tested at the manufacturers premises for the full operating range of the pump to BS 5316 Part 1 .Pump performance shall be within the tolerance limits specified in the above said BS. Y-Strainers shall be provided as the suction side of the pump as shown in GA of UGT Tests

a)

Hydro test pressure on casing shall be 1.5 times maximum discharge head or twice differential head whichever is higher. (Maximum discharge head = shut-off head + maximum suction head). Unless otherwise stated in data sheet A, the hydrostatic tests on the casing shall be conducted for a minimum duration of 30 minutes.

b)

The pumps shall be tested as per IS 11346:2004, at rated speed at MANUFACTURER's works to measure capacity, total head, efficiency and power. These tests shall form the basis for acceptance of pumps except for vibration and noise. The pumps shall be tested over the range covering from shut-off head to the maximum flow. The duration of the test shall be minimum one (1) hour. Minimum five (5) readings approximately equidistant shall be taken for plotting the performance curves.

86

c)

After installation, the pumps shall be subjected to performance testing at site also. If the site performance is found not to meet the requirements regarding vibration and noise as specified, the equipment shall be rectified or replaced by the VENDOR, at no extra cost to the EMPLOYER.

3.15.30

Inspection The contractor shall provide facilities for inspection of the components of the pump during all stages of manufacture to check conformity to specification. The following inspection shall be invariably be witnessed by the Employer. b) Vertical inline pumps - Casing Hydro test, Performance Testing c) General purpose induction motor Performance and characteristics a)

d)

e) f) g) h)

i)

j)

k) l)

m)

n)

Motors shall be capable of giving rated output without reduction in the expected life span when operated continuously under either of the following supply conditions: Variation of supply voltage from rated motor voltage ±10% Variation in supply frequency from rated frequency ±5% Combined voltage and frequency variation ±10% Motors shall be capable of starting and accelerating the load with the applicable method of starting, without exceeding acceptable winding temperature, when the supply voltage is in the range of 85% of the rated voltage. Starting current of motor shall not exceed 200% of rated full load current. Motors shall be capable of satisfactory operation at full load at a supply voltage of 80% of the rated voltage for 5 minutes, commencing from hot condition. Motors shall be capable of developing the rated full load torque even when the supply voltage drops to 70% of the rated voltage. Such operation is envisaged for a period of 1 second. The pull out torque of the motor, to meet this requirement, shall be at least 205% of full load torque. The locked rotor current of the motors shall not exceed (inclusive of 20% tolerance) 600% of full load current for motors. Motors shall be capable of giving rated output without reduction in the expected life span when operated continuously under the specified supply conditions. The locked rotor withstand time under hot conditions at 110% rated voltage shall be more than the starting time at 80% voltage by at least two seconds or 15% of the accelerating time whichever is greater. Motors when started with the drive imposing its full starting torque under the supply voltage variations specified shall be capable of withstanding at least two successive starts from cold condition and one start from hot condition without injurious heating of windings. The motors shall also be suitable for four equally spread starts per hour under the above referred supply conditions.

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3.15.31 Insulation Any joints in the motor insulation such as at coil connections or between slot and winding sections, shall have strength equivalent to that of slot sections of the coil. The insulation shall be given tropical and fungicidal treatment for successful operation of the motor in hot, humid and tropical climate. The motors shall be provided with Class F insulation with temperature rise limited to that of Class B insulation 3.15.32 Temperature rise The temperature rises shall not exceed the values given in IS 12802. Under extremes of supply condition, the temperature rise shall not exceed the value indicated in IS by 10oC. 3.15.33 Constructional features The motor construction shall be suitable for easy disassembly and re-assembly. The enclosure shall be sturdy and shall permit easy removal of any part of the motor for inspection and repair.Motors weighing more than 25 kg shall be provided with eyebolts, lugs or other means to facilitate safe lifting.The rotor bars shall not be insulated in the slop portion between the iron core laminations for squirrel cage motors. 3.15.34 Bearings Unless otherwise specified motor bearings shall not be subjected to any external thrust load. Unless otherwise specified, motor bearings shall have an estimated life of at least 40,000 hrs. The bearings shall permit running of the motor in either direction of rotation. It shall be possible to lubricate the bearings without dismantling any part of the motor. 3.15.35 Terminal box a) Terminal boxes shall be of weather proof construction designed for outdoor service, to eliminate entry of dust and water, gaskets of neoprene or approved equivalent shall be provided at cover joints and between box and motor frame. The cable terminal box shall be right hand side looking from coupling end. b) The terminal box shall be capable of being turned through 360 deg instead of 90 deg. The terminals shall be of the stud type with necessary plain washers, spring washers and check-nuts. Ample phase to phase and phase to ground clearances shall be kept.Suitable cable glands and cable lugs shall be supplied along with the motor. Separate terminal boxes shall be provided for stator leads and space heater.

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3.15.36 Paint and finish All motor parts exposed directly to atmosphere shall be finished and painted to produce a neat and durable surface which would prevent rusting and corrosion. The equipment shall be thoroughly degreased, all rust, sharp edges and scale removed and treated with one coat of primer and finished with two coats of grey enamel paint. 3.15.37 Heating during idle periods Motors rated above 30 kW shall have space heaters suitable for 240V, single phase, 50 Hz, AC supply. Space heaters shall have adequate capacity to maintain motor internal temperature above dew point to prevent moisture condensation during idle period. The space heaters shall be placed in easily accessible positions in the lowest part of the motor frame. 3.15.38 Accessories Motors shall have drain plugs so located that they will drain water, resulting from condensation or other cases from all pockets in the motor casing. The earthing pads shall be of non-corrodible metal welded or brazed at two locations on opposite sides. 3.15.39 Tests a) Motor shall be subjected to all the routine tests as per applicable standard in the presence of the EMPLOYER'S representative. Copies of test certificates of type and routine tests shall be furnished as specified in the distribution schedule, for the EMPLOYER'S approval. The VENDOR shall ensure to use calibrated test equipment/instruments having valid calibration test certificates from standard laboratories traceable to national/international standards b) If type tests have not been carried out on similar Motors, or if the type test reports submitted are not found in order, then VENDOR shall carry out these tests without any extra cost to the Employer. This specification covers the general design, materials, construction features, manufacture, shop inspection and testing at manufacturer‟s works and delivery at site of Horizontal Centrifugal Pumps. 3.15.40

CODES AND STANDARDS The design, materials, construction, manufacture, inspection, testing and performance of horizontal centrifugal pumps shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The equipment shall also conform to latest applicable Indian or equivalent standards. Other international standards are also acceptable, 89

if these are established to be equal or superior to the listed standards. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility. 3.15.41

DESIGN REQUIREMENTS a)

b)

c) d) e) f) g) h) i)

3.15.42

Pumps of a particular category shall be identical and shall be suitable for parallel operation with equal load division. Components of identical pumps shall be inter-changeable. Flow rate versus head curve shall have stable and continuously rising characteristics towards the shut-off head. In case of unstable (drooping) characteristics the duty point shall be well away from the unstable region. Besides the actual flow rate versus head curve, curves for minimum and maximum impeller diameters shall also be shown. The shut-off head shall be at least 110% of the differential head. The required NPSH at duty point shall be at least one (1) metre less than the available NPSH. The rating of the pump driver shall be the larger of the following: The maximum power required by the pump from zero discharge to run-out discharge at site climatic conditions. 110% of the power required at the duty point at site climatic conditions. The corrosion allowance for pressure parts shall be 3 mm Pumps shall run smooth without undue noise and vibration. Noise level produced individually or collectively shall not exceed 85 dB (A) measured at a distance of 1.86 metres from the source in any direction. The overall vibration level shall be as per zones A and B of ISO 10816-1. CONSTRUCTION FEATURES

a) b) c)

d) e)

f) g) h)

In addition to static balancing, impeller and balancing drum shall be balanced dynamically at or near the operating speed. Pump shall be provided with renewable type casing ring. Pump having capacity 1,000 M3/Hr and above shall be provided with impeller ring in addition to casing ring. The hardness of impeller ring shall be 50 BHN higher than that of casing ring. Pump casing shall be provided with drain and vent connection with plugged or valve connection. Bearing shall be oil-lubricated or grease-lubricated and shall have a life of 40,000 hours of working. In case of oil-lubricated bearing, constant oil leveller with magnetic drain plug shall be provided. Replaceable shaft sleeves shall be provided to protect the shaft where it passes through stuffing box. Stuffing box shall be of such design that it can be repacked without removing any part other than the gland and lantern ring. Mechanical seals shall be provided if called for in data sheet - A. If required, a flushing line shall be furnished, complete with strainer and 90

i)

j) k) l)

m)

n) o)

3.15.43

orifice, from the pump discharge to the sealing face. When pumping liquid is not suitable for this purpose, a flushing connection shall be provided so that it can be connected to an external source. All pumps, except for back-pull out type, shall be provided with flexible coupling. Back-pull out type pumps shall be provided with spacer type coupling. Coupling guard made of expanded metal and bolted to the base plate shall be furnished for all coupled pumps. In addition to accessories listed in data sheet A, any other accessories required for safe and efficient operation of pump shall be provided. All incidental piping and valves required for sealing, lubrication and cooling for stuffing box packing and/or bearing of pump shall be furnished by the VENDOR. Leakage from the pump shall be led to the nearest surface drain by OTHERS. Pump vendor shall provide necessary arrangement like drip tray, base plate drain connection etc. TESTS AND INSPECTION

a)

b)

c)

Hydro test pressure on casing shall be 1.5 times maximum discharge head or twice differential head whichever is higher. (Maximum discharge head = shut-off head + maximum suction head). Unless otherwise stated in data sheet A, the hydrostatic tests on the casing shall be conducted for a minimum duration of 30 minutes. The pumps shall be tested as per IS 5120, at rated speed at MANUFACTURER's works to measure capacity, total head, efficiency and power. The negative tolerance on efficiency shall be limited to 2.5% and not 5% as indicated in IS 5120. These tests shall form the basis for acceptance of pumps except for vibration and noise. The pumps shall be tested over the range covering from shut-off head to the maximum flow. The duration of the test shall be minimum one (1) hour. Minimum five (5) readings approximately equidistant shall be taken for plotting the performance curves. After installation, the pumps shall be subjected to testing at site also. If the site performance is found not to meet the requirements regarding vibration and noise as specified, the equipment shall be rectified or replaced by the VENDOR, at no extra cost to the EMPLOYER.

3.15.44 PERFORMANCE GUARANTEE Performance parameters to be guaranteed by the VENDOR and tolerances permitted shall be as indicated. BIDDER shall confirm acceptance of these by

91

indicating values in data sheet B. Pump or any portion thereof is liable for rejection, if it fails to give any of the guaranteed performance parameters. 3.16 SUBMERSIBLE PUMPS FOR WASTE WATER 3.16.1 SCOPE This specification covers the general design, materials, manufacture, shop inspection and testing at manufacturer‟s works, delivery at site, handling at site, installation, testing, commissioning and carrying out performance test of submersible pumps for waste water with their accessories. 3.16.2 CODES AND STANDARDS The design, materials, manufacture, inspection, testing and performance of the submersible (waste water) pumps shall comply with all currently applicable statutes, regulations and safety codes in the locality where equipment is to be installed. The equipment shall also conform to the latest editions of the relevant codes and standards existing as on the date 180 days prior to the deadline for submission of bids, unless otherwise specified. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility. 3.16.3 DESIGN REQUIREMENTS a) Pump shall be submersible, non-clog, wet & dry pit installation, fixed or portable type and shall be suitable for working with the minimum liquid level.The Pump shall be designed to handle solid sizes Fixed type pump set shall be with control panel with all safety devices.The pump shall be capable of delivering the required flow rate for both continuous and intermittent operations, at the specified operating conditions. The pump shall be designed to have minimum maintenance and easy accessibility to all components.Flow rate versus head curve shall have stable and continuously rising characteristics towards the shut-off with the highest at shut off. In case of unstable (dropping) characteristics the duty point shall be well away from the unstable region. Besides the actual flow rate versus head curve, curves for minimum and maximum impeller diameters shall also be shown. b) c) Pumps of a particular category shall be identical and shall be suitable for single as well as parallel operation with equal load division at any point in between the maximum and minimum system resistance. Components of identical pumps shall be inter-changeable. d) Pumps shall run smooth without undue noise and vibration. Noise level produced individually or collectively shall not exceed 85 dB (A) measured at a distance of 1.0 metres from the source in any direction. The overall vibration level shall be as per zones A and B of ISO 10816-1. e) The power rating of the pump driver shall be the larger of the following considering the frequency variation indicated in Data Sheet -A: f) The maximum power required from zero discharge to run-out discharge at site climatic condition.

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g)

110% of the power required at any operating point in between the maximum and minimum system resistance curves for any combinations of pumping. h) 115% of the power required at the design point. i) The critical speed of the pump shall be not less than 130% of the normal operating speed of the pump.The pump set shall be capable of withstanding the accidental rotation in reverse direction. The direction of rotation shall be clockwise viewed from the drive end. 3.16.4 CONSTRUCTION FEATURES a) Pump casing shall be of robust construction. Liquid passages shall be finished smooth and designed as to allow free passage of solids and stringy materials. b) c) Impeller shall be non-clog, vortex or vane type with smooth blunt inlet edge and large waterways so as to allow free passage of the large size solids. It shall be free from sharp corners and projections likely to catch and hold rags and stringy materials. The impeller shall be statically and dynamically balanced. Pumps up to 1000 M3/Hr shall have maximum 2 vanes; pumps having capacity 1000 M3/Hr and above shall have maximum 3 vanes. d) Double Mechanical seals shall be provided to protect the motor from ingress of waste water along the shaft. The preliminary and secondary seals shall be oil- lubricated with tungsten carbide or silicon-carbide faces and they should be equipped with an electrical monitoring system for seal failure detection. e) Motor and Pump shall have a common shaft with bearings. The bearing shall be permanently greased and maintenance free. f) Portable type submersible pump should be equipped with pump base stand / legs, adequate length of chain and flexible type discharge hose pipe suitable for directly lowering into the well. g) Fixed type submersible pump shall be provided with a 90° duck foot bend for fixing to the concrete floor of the well. The joint between the pump discharge flange and the delivery piping shall be made by merely lowering the pump into guide system at the access level. It shall be provided with all necessary fixings for guiding the pumps during lifting/lowering. h) Replaceable shaft sleeves shall be securely locked or keyed to the shaft to prevent loosening. The surface hardness of the shaft sleeve shall be minimum. i) In addition to accessories listed in data sheet A, any other accessories required for safe and efficient operation of pump shall be provided. 3.16.5 3.16.6

3.16.7 PERFORMANCE AND CHARACTERISTICS a) Motors shall be capable of giving rated output without reduction in the expected life span when operated continuously under varying voltage and frequency supply conditions as called for in Data Sheet - A. b) Motors shall be suitable for full voltage direct-on-line starting or star-delta starting. c) The starting current of motor shall not exceed 200% of rated full load current for star/delta starting and 600% of rated full load current for DOL starting, under any circumstances. d) Motors shall be capable of starting and accelerating the load with the applicable method of starting, without exceeding acceptable winding temperatures, when the supply voltage is in the range 85% of the rated motor voltage to maximum permissible voltage, for category B type motors. e) The locked rotor current of the motor shall not exceed 600% of full load current (subject to tolerance as per the applicable standard). f) Motors shall be designed to withstand 120% of rated speed for two minutes without any mechanical damage, in either direction of rotation. g) The motor vibrations shall be within the limits specified in applicable standard unless otherwise specified for the driven equipment. h) Except as mentioned herein, the guaranteed performances of the motor shall be met with tolerances specified in applicable standard (IS: 9283:2013). i) Protection against increase in stator winding temperature, bearing temperature, leakage in stator housing and terminal box shall be provided. Minimum 3 nos. thermostats in series to be provided to sense the stator winding temperature. Sensors to be provided to detect leakage of waste water into oil housing. 3.16.8 SUBMERSIBLE CABLE a) The cable shall be PVC insulated and PVC sheathed, flexible, 3 core flat type. The size of the conductor shall be adequate for continuous use under water and air. b) In case a joint is required to be made between the lead cable supplied with the motor and the user's cable connectors, a detailed procedure of cable jointing to make a watertight joint shall be provided by the manufacturer. c) The size of the conductor and length of cable should be suitably selected so that the voltage drop at motor terminals does not exceed 3 percent of the rated voltage. 3.16.9 EARTHING a)

Earthing of the motor shall be done in accordance with the relevant provisions of IS: 3043:1987.

b)

For fixed installation, earthing connection may be made to discharge pipe clamp.

94

3.16.10 INSULATION Any joints in the motor insulation such as at coil connections or between slot and end winding sections shall have strength equivalent to that of the slot sections of the coil. The insulation shall be given tropical and fungicidal treatment for successful operation of the motor in hot, humid and tropical climate. The tropical sing treatment shall be as per the applicable standard. 3.16.11

TEMPERATURE RISE The temperature-rise test of the motor shall be taken with the motor coupled to the suitable pump to give the full load output of the motor. When the various temperatures are stabilized, the set is stopped and the temperature-rise of the stator winding by the resistance method shall not exceed 35°C at rated voltage and 45°C at 85% of the rated voltage. During the test, the temperature of the cooling water may not exceed 45°C. As the cable resistance will also be substantial, it is necessary that while calculating the temperature rise by resistance method, due care is taken to account for the correct hot and cold resistance of windings. 3.16.12 CONSTRUCTION FEATURES OF MOTOR The motor shall be suitable for continuous use in fully or partially submerged condition. A built-in cooling system if required shall be provided to allow the motor to operate continuously at its rated output regardless of whether the electric motor is submerged or not by providing either external or internal cooling arrangement. 3.16.13 TESTS AND INSPECTION a) Hydro-test pressure on casing shall be 1.5 times maximum discharge head or twice differential head whichever is higher. Maximum discharge head is defined as the sum of the shut-off head and maximum suction head. Unless otherwise stated in data sheet A, the hydrostatic tests on the casing shall be conducted for a minimum duration of 30 minutes. b) The pumps shall be tested in accordance with HIS, ISO 9906 and IS 5120, at rated speed at MANUFACTURER's works to measure capacity, total head, efficiency and power. The negative tolerance on efficiency shall be limited to 2.5% and not 5% as indicated in IS 5120. These tests shall form the basis for acceptance of pumps except for vibration and noise. The pumps shall be tested over the range covering from shut-off head to the maximum flow. The duration of the test shall be minimum one (1) hour. Minimum five (5) readings approximately equidistant shall be taken for plotting the performance curves. c) After installation, the pumps shall be subjected to testing at site also. If the site performance is found not to meet the requirements regarding vibration and noise as specified. The equipment shall be rectified or replaced by the VENDOR, at no extra cost to the EMPLOYER. 3.16.14 PERFORMANCE GUARANTEE

95

Performance parameters to be guaranteed by the VENDOR and tolerances permitted shall be as indicated. BIDDER shall confirm acceptance of these by indicating values in data sheet B. Pump or any portion thereof is liable for rejection, if it fails to give any of the guaranteed performance parameters. 3.16.15 DRAWINGS The following drawings shall be submitted by the BIDDER along with their proposal.Preliminary outline dimensional drawing showing details of pump set, installation details, civil foundation, clearances, minimum submergence, etc. Performance curves for capacity vs total head, efficiency, and input to motor. The capacity range shall be zero flow to run out flow.Typical cross sectional drawing showing constructional details.

3.16.16 BID EVALUATION For every kW of differential power input to the motor at duty point, pump sets will be cost loaded at the rate specified in data sheet A. 3.16.17 Submersible These shall be fully submersible with a fully submersible motor. The pumps shall be provided with an automatic level controller and all interconnecting power and control cabling which shall cause the pumps to operate when the water level in the sump rises to a preset level and stop when the preset low level is reached. Pumps for drainage shall be single stage, single entry. Pump shall be C.I. casing and C.I. two vane open type with a dynamically balanced impeller connected to a common shaft of the motor. The vane for sewage pump will be open type, while for drainage pump, etc. it will be of semi open type. The MOC of the sump shall be in accordance to schedule of quantity. Stuffing box shall be provided with mechanical seals. Each pump shall be provided with a suitably rated induction motor suitable for 415 volts, 3 phase, 50 Hz A.C. power supply. Each pump shall be provided with in built liquid level controller for operating the pump between predetermined levels. The pumping set shall be for stationary application and shall be provided with pump connector unit. The delivery pipe shall be joined to the pump through a rubber diaphragm, and bend and guide pipe for easy installation. Pump shall be provided with all accessories and devices necessary and required for the pump to make it a complete working system. Sump pump shall be complete with level controllers, power and control switch gear, Auto/off/Manual switches, pumps priority selections and control and power cabling upto motor and controller/probes etc. (Including earthing). Level control shall be such that one pump starts on required level, 2nd pump cuts in at high level and alarms is given at extra high level. All level controllers shall be provided with remote level indications 3.16.18

Motor Design

96

The pump motor shall be a squirrel cage induction, housed in air filled water-tight enclosure. Oil filled motors are not acceptable. The stator windings shall be Class "F" insulation (155 degree C or 311 degree F) for general usage and class `H' insulation (180 degree C or 317-8 grade 2) for submersible type. The stator shall be heat shrunk fitted into the enclosure and shall not use bolts, pins or other fasteners that penetrate through the stator enclosure. The starter shall be equipped with a thermal switch embedded in series in the coils of the stator windings to protect the stator from wheel.The motors shall be designed for continuous running duty type at 415 volts, 3 phase, 50 Hz power supply and capable of sustaining a minimum of 20 starts/stops per hour.Between stator housing and pump, a tandem seal arrangement will be provided with an oil barrier. Both seals run in oil, allowing dry running without seal damage. Both seals shall be of the rubber bellows or metallic bellow type with positive drive between shaft and rotating seal face. 3.17 PLUMBING SYSTEM-ELECTRICAL REQUIREMENTS 3.17.1 SCOPE OF WORK a) b) c) d)

Power and Control cabling from MCC to Plumbing pumps panel including cable carrier system. Local Push button station Earthing system above ground Structural steel for supporting the panels, LPBS, Cable trays etc.

3.17.2 ELECTRICAL PANELS a) b)

c)

d)

The Contractor‟s scope includes 1 No. MCC for Plumbing System. 415 Volts, 50 Hz, TPN supply at the incomer of MCC will be made available by the Employer. Further distribution of power and derivation of any other voltage shall be in Contractor‟s scope. MCC incomer shall be suitable for termination of 1RX3.5CX120 sqmm, AL, XLPE The Contractor‟s scope includes 1 No. MCC for Plumbing System. All potential free contacts (Feedback & command from PLC) shall be wired upto Marshalling compartment of MCC.

3.17.3 LOCAL PUSH BUTTON STATIONS (LPBS) a) b)

LPBS for motors shall be provided by contractor. Necessary supporting structural steel for the same is in Contractor‟s scope. LPBS shall be metal enclosed, weather proof, dust and vermin-proof, suitable for mounting on wall or structures. The enclosure shall be sheet steel, 2 mm thickness and shall have degree of protection not less than IP55. The enclosure shall be painted with one coat of epoxy primer and two coats of Epoxy Light Gray paint – 631 shade as per IS-5. 97

415 Volts, 50 Hz, TPN supply at the incomer of MCC shall be made available by the Employer. Further distribution of power and derivation of any other voltage shall be in Contractor‟s scope. Termination of incomer and outgoing cables is in scope of contractor. Earthing above ground shall be considered in contractor‟s scope as per clause no.2.5

3.17.8 Any other make subjected to prior approval of Employer / Project Manager 3.18 COMMISSIONING & GUARANTEE 3.18.1 SCOPE OF WORK a) Work under this section shall be executed without any additional cost. The rates quoted in this tender shall be inclusive of the works given in this section. b) Contractor shall provide all tools, equipment, metering and testing devices required for the purpose. c) On award of work, Contractor shall submit a detailed proposal giving methods of testing and gauging the performance of the equipment to be supplied and installed under this contract. 100

d)

e)

f)

All tests shall be made in the presence of the Architect or his representative or any inspecting authority. At least five working days notice in writing shall be given to the inspecting parties before performing any test. Water flow rates of all equipment and in pipe lines through valves shall be adjusted to design conditions. Complete results of adjustments shall be recorded and submitted. Contractor shall ensure proper balancing of the hydraulic system and for the pipes / valves installed in his scope of work by regulating the flow rates in the pipe line by valve operation. The contractor shall also provide permanent Tee connection (with plug) in water supply lines for ease of installing pressure gauge, temperature gauge & rota meters. Contractor shall also supply all required pressure gauge, temperature gauge for system commissioning and balancing. The balancing shall be to the satisfaction of Project Manager / Project Manager.

3.18.2 PRECOMMISSIONNIG a) b)

c) d)

e) f) g) h) i) j) k)

On completion of the installation of all pumps, piping, valves, pipe connections, insulation etc. the Contractor shall proceed as follows: Prior to start-up and hydraulic testing, the Contractor shall clean the entire installation including all fitments and pipe work and the like after installation and keep them in a new condition. All pumping systems shall be flushed and drained at least once through to get rid of contaminating materials. All pipes shall be rodded to ensure clearance of debris, cleaning and flushing shall be carried out in sections as the installation becomes completed. All strainers shall be inspected and cleaned out or replaced. When the entire systems are reasonably clean, a pre-treatment chemical shall be introduced and circulated for at least 8 hours. Warning signs shall be provided at all outlets during pre-treatment. The pre-treatment chemical shall: Remove oil, grease and foreign residue from the pipe work and fittings; Pre-condition the metal surfaces to resist reaction with water or air. Establish an initial protective film; After pre-treatment, the system shall be drained and refilled with fresh water and left until the system is put into operation. Details and procedures of the pre-treatment shall be submitted to the Architect for approval. Check all clamps, supports and hangers provided for the pipes. Check all the equipment, piping and valves coming under hot water system and operate each and every valve on the system to see if the valves are functioning properly. Thereafter conduct & hydro test of the system as for (b) above.

101

l)

Fill up pipes with water and apply hydrostatic pressure to the system as given in the relevant section of the specification. If any leakage is found, rectify the same and retest the pipes.

3.18.3 STATUTORY AUTHORITIES' TESTS AND INSPECTIONS a)

b)

c)

d)

e)

As and when notified in writing or instructed by the Architect, the Contractor shall submit shop drawing and attend all tests and inspections carried out by Local Fire Authorities, Water Authority and other Statutory Authorities, and shall forthwith execute free of charge any rectification work ordered by the Architect as a result of such tests and inspections where these indicate non-compliance with Statutory Regulations. Some of these tests may take place after the issue of Practical Completion of the Main Contract and the Contractor shall make all allowances in this respect. The Contractor shall be responsible for the submission of all necessary forms and shop drawings to the Statutory Authorities which shall conform in layout to the latest architectural plans submitted to and kept by these Authorities. The submission shall comply with the requirements set forth in the current Codes of Practice and circular letters of the Statutory Authorities. The shop drawings to be submitted shall be forwarded to the Architect for checking before submission. The Contractor shall allow for at least two submissions of complete sets of shop drawings to the Authorities, one to be made within six months after the award of the Contract but not less than six weeks before the inspection. The Architect may at his discretion instruct the Contractor for additional submissions to the Local Authorities whenever necessary. The Contractor shall notify the Architect at least seven days in advance of his application for local Authority tests and inspections. On receipt of a confirmed date for test and inspection the Contractor shall inform the Architect without delay.

3.18.4 FINAL ACCEPTANCE TESTS a)

b)

Following commissioning and inspection of the entire installation, and prior to issue of the Completion Certificate, the Contractor shall carry out final acceptance tests in accordance with a programme to be agreed with the Architect. Should the results of the acceptance tests show that plant, systems and/or equipment fail to perform to the efficiencies or other performance figures as given in this Specification, the Contractor shall adjust, modify and if necessary replace the equipment without further payment in order that the required performance is obtained.

102

c)

Where acceptance tests are required by the relevant Authorities having jurisdiction, these tests shall be carried out by the Contractor prior to the issue of Completion Certificate to the acceptance of the Authorities.

3.18.5 REJECTION OF INSTALLATION / PLANT a)

b)

Any item of plant or system or component which fails to comply with the requirements of this Specification in any respect whatsoever at any stage of manufacture, test, erection or on completion at site may be rejected by the Architect either in whole or in part as he considers necessary/appropriate. Adjustment and/or modification work as required by the Architect so as to comply with the Authority's requirements and the intent of the Specification shall be carried out by the Contractor at his own expense and to the satisfaction of the Authority/Architect. After works have been accepted, the Contractor may be required to carry out assist in carrying out additional performance tests as reasonably required by the Architect/Employer.

3.18.6 WARRANTY AND HANDOVER The Contractor shall warrant that all plant, materials and equipment supplied and all workmanship performed by him to be free from defects of whatsoever nature before handover to the Employer. 3.18.7 HANDING OVER OF DOCUMENTS All testing and commissioning shall be done by the Contractor to the entire satisfaction of the Employer‟s site representative and all testing and commissioning documents shall be handed over to the Employer‟s site representative. The Contractor shall also hand over all maintenance and operation manuals, all certificates and all other documentation as per the terms of the contract to the Employer‟s site representative.

3.18.8 CHECKLIST FOR COMMISSIONING. 3.18.9 Water Supply& Drainage Equipment a) Operate each and every valve on the system to see if the valves are functioning properly. b) Check all clamps, support and hangers provided for the pipes. c) Check rotation of each motor and correct the same if required. d) All the pumps shall run continuously for one hour. Record the pressure and motor current and voltage readings. e) Check all annunciations by simulating the alarm conditions if any at site. f) Remove grease trap manhole covers. Check for cleanliness, check for partitions, and put back the cover.

103

g)

h) i) j)

Remove manhole covers on sewer lines, inspect for cleanliness. After they are found to be clean, pour water into the first manhole and see that all the lines are clear. Make sure that all the covers are put back after the inspection. Check gully traps by opening of covers and check that water seal in the traps are maintained. Check for general cleanliness. Check installation of proper vents and cowls at the roof level for all soil and waste pipes. Performance test to be carried out and recorded in the following table for the pumps.

(Similar Readings shall be taken for all other pumps) Simulate low level in the domestic water tanks to trip domestic Filter Feed Pumps. Simulate high level in treated water tanks to trip softener feed pumps. Simulate low level in treated water tanks to trip treated water hydro-pneumatic pumps. Submersible Sump Pumps Fill the sump with water, while observing the level. Keep the pump starter switch on „OFF‟ position to check for start of pump. By keeping the starter switch on „Auto‟ position, both the pumps should start. As the water level starts receding, one pump should switch off by itself. The second pump should switch off on further reduction in water level. Fill the sump with a little water and check both the pumps in „Manual‟ position momentarily. Leave the switches in „Auto‟ position for both the pumps. 104

3.19 DATA SHEETS 3.19.1 BUTTERFLY VALVES SL. NO. 1.0

DATA SHEET A BUTTERFLY VALVES ITEM

UNIT

Blank Spaces to be filled by vendor

No.

As per BOQ

GENERAL

1.1.

SERVICE

1.2.

TAG NOs.

1.3.

NO. OF VALVES

1.4.

DESIGN STANDARD

1.5.

VALVE CATEGORY

1.6.

DISC

1.7.

BODY TYPE

1.8.

VALVE SIZE

1.9.

VALVE RATING / CLASS

1.10.

FLUID HANDLED WITH ITS SPEC. GRAVITY

1.11.

COMPANION FLANGE TYPE AND CLASS

ANSI B16.5 Class 150

1.12.

TYPE OF VALVE OPERATOR



Cast Iron NB

65 mm to 150 mm PN 10

MAXIMUM FLOW (INDICATE THE RELATED PRESSURE ALSO)

M3/hr, KPa

1.14.

MAXIMUM FLOW VELOCITY

m/s

1.15.

DESIGN PRESSURE

KPa

1.16.

OPERATING PRESSURE

KPa

1.17.

DESIGN TEMPERATURE

0

C

1.18.

OPERATING TEMPERATURE

0

C

1.19.

VALVE LOCATION

MAX.

MIN.

OPE R A T I N G

1.13.

105

SL. NO.

4.0

DATA SHEET A BUTTERFLY VALVES ITEM

UNIT

Blank Spaces to be filled by vendor

MATERIALS OF CONSTRUCTION CAST IRON

4.1



BODY

3.2.



DISC

3.3.

STEM

STAINLESS STEEL

3.4.

SEAT

EPDM

3.5.

BODY SEAT RINGS

3.6.

DISC SEAL RINGS

3.7.

SEAT RETAINING RINGS

3.8.

COMPANION FLANGE

5.0

CAST IRON

TESTS AND INSPECTION HYDROSTATIC TEST PRESSURE FOR BODY

Kg/cm2

15 BAR

4.2.

HYDROSTATIC TEST PRESSURE FOR DISC

Kg/cm2

15 BAR

4.3.

DISC STRENGTH TEST PRESSURE

Kg/cm2

4.4.

ACTUATOR PERFORMANCE TEST PRESSURE

Kg/cm2

4.5.

AIR LEAK TEST PRESSURE

Kg/cm2

4.6.

ELECTRICAL CONTINUITY TEST

4.7.

SPARES

4.1.

6.0

DISC SEAL RINGS

5.1.

FLANGE GASKET

5.2.

SEAT/SEAL CLAMPING BOLTS

5.3.

'O' RING SEALS OR GLAND 106

SL. NO.

DATA SHEET A BUTTERFLY VALVES ITEM

UNIT

Blank Spaces to be filled by vendor

PACKING 5.4.



(REF. NOTE -10)

NOTES :1. FOR GENERAL REQUIREMENTS. HOWEVER, IN CASE OF OVERLAPPING REQUIREMENTS, THOSE OF THE DATA SHEET A, TO BE CONSIDERED AS THE FINAL ONE. 2. THE VALVE SHALL BE DESIGNED CONSIDERING THE LARGER OF THE FOLLOWING TORQUE REQUIREMENTS FOR WHICH CALCULATIONS SHALL BE SUBMITTED: a) CALCULATED AS PER AWWA-C504-80 b) CALCULATED AS PER THE STANDARD TO WHICH VALVE IS DESIGNED. 3. FOR MANUALLY OPERATED VALVES, TORQUE REQUIRED AT HAND WHEEL SHALL NOT EXCEED 7 KG.M. 4. MOTOR OPERATED VALVE ACTUATOR SHALL BE RATED TO PROVIDE AN OUTPUT TORQUE OF ATLEAST 150% OF TORQUE REQUIRED AS PER NOTE-2 ABOVE UNLESS OTHERWISE NOTED. 5. THE ACTUATOR SHALL BE CAPABLE OF OPERATING IN ANY MOUNTING ANGLE. 6. THE TRANSMISSION UNIT SHALL BE DESIGNED TO TRANSMIT TWICE THE VALVE DESIGN TORQUE UNLESS OTHERWISE NOTED. 7. THE ACTUATOR SHALL PROVIDE AN UNSEATING TORQUE OF AT LEAST 50% IN EXCESS OF VALVE SEATING TORQUE AT THE SPECIFIED VOLTAGE UNLESS OTHERWISE NOTED. 8. SEGMENTAL WELDED CARBON STEEL FLANGE PLATES ABOVE 20 MM THICKNESS SHALL BE SUBJECTED TO PREHEATING BEFORE WELDING AND STRESS RELIEVING AFTER WELDING AS PER IS 2825 UNLESS OTHERWISE SPECIFIED. 9. UNLESS OTHERWISE SPECIFIED IN BOQ , ONE COAT OF ZINC RICH PRIMER AND TWO COATS OF ENAMEL SHALL BE APPLIED TO ALL STEEL AND CAST IRON EXPOSED SURFACES. THE MINIMUM THICKNESS OF COATING SHALL BE 100 MICRONS. 10. THE VENDOR MAY ALSO SUGGEST ANY ADDITIONAL SPARES AND TOOLS REQUIRED FOR THE SUCCESSFUL OPERATION, START UP AND MAINTAINENCE OF THE VALVE. 11. IN THE ABSENCE OF ANY TEST RELATED DATA, THE RELEVANT

All accessories shall be supplied as specified. In addition, any other accessories required shall be supplied without any price implication to make the measurement complete to match with process requirement.

* - Bidder to furnish details. All accessories shall be supplied as applicable. The bidder shall indicate all applicable codes and standards The solenoid coil shall operate the valve even when the supply voltage drops down by 15% or goes up by 10%. The coil shall be wired to a terminal block located inside the housing. Flying lead wires of the coil are not acceptable.the material of housing shall be metallic unless otherwise indicated in data sheet. Each solenoid valve body shall be subjected to pneumatic pressure test by air / nitrogen with test pressure not less than 1.5 times the maximum working pressure (rated) of the valve. There shall not be any visible leakage during the test Each solenoid valve shall be subjected to seat leakage test by air / nitrogen with test pressure equal to maximum working pressure (rated) of the valve for one minute. There shall not be any seat leakage during this test. The coil shall be low power consumption type. Generally the power consumption of coil shall be less than 5 W.

120

3.19.7 ELECTRICAL TECHNICAL DATA SHEETS

For MCC +PDBs+MLDBs/SLDBs/DBs ( To be filled by the bidders)

S.No.

Description

Recommended Specification

1

Type of Panel

a.

MCC non drawout type compartmentalized.

b.

Panels non drawout type,

Confirmation by the Bidders

non compartmentalized

2

Type of Mounting

Free standing Floor Mounted

3

Fault kA

50kA -1 Sec for MCC

4

Thickness of CRCA sheets

a

Structural members

3mm

b

Covers and doors

2mm

c

Base channel

MCC - ISMC 100

d

Gland plate

3mm

5a.

Painting/ Process

Synthetic Enamel Paint

121

As per seven tank process Oven baked. b

Paint shade; a. Inside

RAL – 7032

b. Outside

RAL - 7032

6

Details of busbars

Electrolytic grade Copper of specified rating for details see constructional features mentioned in specifications

7

Cable Entry

For MCC & other Panels Top or Bottom depending upon location of Panel.

8

Enclosure

For MCC – IP -52 with louvers for Ventilation.

Protection/ Ventilation

9

Control Wiring/

Insulated 660Volts Cu wire.

Power Wiring a.

Voltage Circuit

1.5 sq mm

b.

Current Circuit

2.5 sq mm

c.

Minimum size of Power wiring

16 sq mm

122

CKt

10

Maximum Operating Height

2100

11

Mounting height of Relays/Meters

Range 350mm to 1900mm

Control Switches

3.19.8 CONSTRUCTIONAL FEATURES FOR MCC

S.No.

Description

Recommended Specification

1

MCC

a.

Busbar Chamber

400mm ht

b.

Metering Chamber

400mm ht

c.

Incoming Compartment

1000mm vide Module

Confirmation by the Bidders

Single Tier

123

d.

Overall Height

2100 mm

e.

Overall Depth

1300 & 900 mm

f.

Overall Length

( To be indicated by the bidder)

g.

Construction

IP-52 with louvers for ventilation

h.

Current Density

1.25 Amp / Sq.mm

i.

Main Bus

1.75 Amp / Sq.mm

ii.

Branch Bus Rating

75% of aggregate Switches connected. 1.25 Amp / Sq.mm Density

iii.

Neutral Bus

Half of the size of phase bus

iv.

Earth Bus

Half of the size of phase bus

j.

Incoming and outgoing feeders.

As per SLD

124

3.20 LIST OF APPROVED MAKES FOR PLUMBING AND SANITARY WORKS NOTE: - All materials and products shall conform to the relevant standards and shall be of approved make and design. A list of manufacturers/ vendors is given separately herein below for guidance. The Engineer shall give the approval of a manufacturer/ vendor/ only after review of the sample/ specimen. In case the same is not available in the market or in case of change in trade name, equivalent makes/ re-designated manufacturer then an equivalent approved make shall be used with the approval of Employer/ Engineer. The complete system and installation shall also be in conformity with applicable Codes & Standards and Tender specifications. - Only “First” class quality materials shall be used. - Employer reserves the right to choose any of the approved make / vendors as per this list. - In case of products not indicated in this list, bis marked products shall be preferred. - Specification of manufacturer‟s item shall be checked against tender item / specifications before selecting any product or brand name. In case of any discrepancy, tender item/ specifications shall prevail, and any such brand of item shall not be used which is not conforming to tender specifications even if it is listed in this list. - For use of material from a bis listed/ certified manufacturer, the contractor shall furnish a copy of the BIS certificate to Employer before procuring the material. - In case non-availability of any item/ material among approved manufacturers/ brands at a particular site/ region, alternate manufacturers/ brands conforming to BIS/ BS etc. shall be used subject to approval by Employer. - In case of non-availability of any manufacturer among approved manufacturers at a particular site/ region, alternate manufacturer‟s name shall be proposed along-with required credentials for Employer‟s approval. - In case of any item/ product neither covered in this list nor having A BIS specifications, the contractor shall submit the proposed item/ product along-with technical details/ specifications (as per bid), test certificates etc. And other credentials of the manufacturer for Employers approval.

125

LIST OF APPROVED MAKES FOR PRODUCTS AND MATERIALS FOR PLUMBING AND SANITORY WORKS ARE INDICATED IN THE TABLE BELOW. HOWEVER, ANY OTHER MAKE WHICH IS EQUIVALENT AND MEETING THE TENDER SPECIFICATIONS ARE ALSO ACCEPTABLEWITH PRIOR APPROVAL OF THE ENGINEER S.No.

Details of Materials / Equipment

Manufacturer’s Name

1.

a.

Hindustan

Vitreous China Sanitaryware

Parryware /or Approved Local

2.

W.C Seat Covers

Admiral Tara or Approved Local

3.

a.

Low level Flushing cisterns

Commander Duralite or Approved Local

b.

WC Connectors

Multiwik Viega or Approved Local

4.

Bath Tub and Shower Tray

Aquaplus Parryware or Approved Local

126

5.

Stainless Steel Sink

Cobra or Jayna Nirali Approved Local

6.

Cistern

Commandor or Approved Local Champion Parryware

7.

CP Brass Fittings

Parryware or Approved local

8.

Flow Control Devices

Jaquar RST or Approved Local

9.

Storage Type Geyser

Bajaj Venus or Approved Local

10.

Floor Drain Fixture, Rain Water Outlets

ACO GMGR Neer or Approved Local

127

11.

Urinal Trap

Chilly Neer or Approved Local

12.

13.

ULTRA LOW FLOW FIXTURES-

Hindware

(Flush valves, Faucets, Bib taps)

Parryware

Low Flow C.P Fittings

or Approved Local

Water Cooler

Aquaguard Blue star or Approved Local

14.

C.P. Grating for Floor Trap

Chilly GMGR Neer or Approved Local

16.

GI pipes fittings

Crescent Engg Jalandhar

Corp.

KS Engg RM

Engg works, ahmedabad

Zoloto or Approved Local

17.

GI/MS Pipe Protection Wrapping & Coating

IWL - Pypkote Neotape

128

Rustech – Coatek STP

18.

Pipe clamp & supports

Ltd. or Local

Approved

Diamond Easyflex Intellotech or Local

19.

Pipe Hangers

Approved

Hitech OM fasteners or Approved Local

20.

RO UNIT

Aqua Guard Kent Konark or Approved Local

21.

UPVC Pipe

Finolex Jain Kisan Prince

22.

CPVC pipes & fittings

Ajay Ashirwad

129

Astral Prince

23.

Teflon Tape

Approved local

24.

Toilet Accessories

Akoi Parko or Approved local

25.

GM / Forged Brass Ball Valves

Jayhiwa Leader Zoloto or Approved local

26.

Gate Valve / Sluice Valves

Advance Kirloskar Jainsons SANT Zoloto

27.

Butterfly Valve

Zoloto Jayhiwa Pipeline Products or Approved local

28.

Check Valve – WaferType

Kirloskar Jayhiwa

130

Zoloto or Approved local

29.

Check Valve – Dual Plate

Normex Sant Pipeline Products or Approved local

30.

Cast Iron Non Return valve

Leader Zoloto Pipeline Products or Approved local

31.

Check Valve Forged Screwed

Leader Pipeline Products RB Zoloto

32.

Pressure Reducing Valve

RB OR

33.

Solenoid Valve

Zoloto Avcon Uflow Danfoss or local approveds

34.

Thermostatic mixing valve

Danfoss Overtrop

35.

Air Release Valve

OR Pipeline Products Zoloto 131

36.

Ball Float Valve

Prayag Zoloto Leader or local

37.

NRV – Ball type – Sewage application

Danfoss or Approved local Silverspark Normex

38.

HDPE Tanks

Sintex or Approved local Ashish

39.

Air Vent Inlet Valve

Jainsons SKS Studor

40.

FRP/GRP- SMC water tank

Devi Polymers pvt. Ltd. Approved local /Binani

41.

FRP/GRP storage tanks

Sintex or Approved local

42.

Y Strainer CI

Leader or Approved local Pipe line products Zoloto

43.

Storm Water Drainage & Sewage Sump Pumps (Submersible)

Aquasub Engineering HBD 132

Kirloskar KSB

44.

Transfer Pumps

Aquasub Engineering CRI Pumps HBD Kirloskar Lubi/Local

45.

Self-Priming Pumps

Aquasub Engineering CRI Pumps Johnson Kirloskar Lubi/Local

46.

Borewell Pump

Aquasub Engineering CRI Pumps Grundfos Kirloskar

47.

Anti Vibration Mounting & Flexible Connections

Easyflex Resistoflex

48.

Pressure Gauge

Fiebig H Guru 133

49.

Water Meter (Mechanical Type)

Capstan or local

Approved

Kranti Kent 50.

Level Controller & Indicator (Water)

Pumptrol or Approved local RM Engg. Works, Ahmedabad

51.

Paints

Asian Paints Berger ICI Shalimar Paints

52.

MH / Water Tank Plastic Steps

KGM or Approved local Patel Pranali Industries

53.

Insulation for Hot Water Pipes

Armacell or

Approved Armaflex

local

K-Flex Thermaflex 54

Electric Hot Water Generator / Heat Pump

A.O. Smith Bajaj Venus 134

55.

Solar Heating

A.O Smith Vijay Solar Overtrap Honeywell

56.

Grease Trap/Separator

ACO Kessels Wade

57.

Welding Rods

Ador Cosmos Prima (S) Super Bond (S)

58.

Fastener

Fisher Hilti

59.

Fire Sealant

Birla 3 M, Hilti Promat

135

60.

Level Indicator

HELLY, PUMPTROL TECHNIKA, TECHTROL

61.

Temperature Sensor

Forbes Marshall Danfoss

61.

Level Switch

SBEM Wika RK DUTT

3.21 -

-

-

-

-

Chemtrol APPROVED MAKES/ MANUFACTURERS( Electrical Equipments): NOTE: All materials and products shall conform to the relevant standards and shall be of approved make and design. A list of manufacturers/ vendors is given separately herein below for guidance. The Engineer shall give the approval of a manufacturer/ vendor/ only after review of the sample/ specimen. In case the same is not available in the market or in case of change in trade name, equivalent makes/ re-designated manufacturer then an equivalent approved make shall be used with the approval of Employer/ Engineer. The complete system and installation shall also be in conformity with applicable Codes & Standards and Tender specifications. Only “First” class quality materials shall be used. Employer reserves the right to choose any of the approved make / vendors as per this list. In case of products not indicated in this list, bis marked products shall be preferred. Specification of manufacturer‟s item shall be checked against tender item / specifications before selecting any product or brand name. In case of any discrepancy, tender item/ specifications shall prevail, and any such brand of item shall not be used which is not conforming to tender specifications even if it is listed in this list. For use of material from a bis listed/ certified manufacturer, the contractor shall furnish a copy of the BIS certificate to Employer before procuring the material. In case non-availability of any item/ material among approved manufacturers/ brands at a particular site/ region, alternate manufacturers/ brands conforming to BIS/ BS etc. shall be used subject to approval by Employer. In case of non-availability of any manufacturer among approved manufacturers at a particular site/ region, alternate manufacturer‟s name shall be proposed along-with required credentials for Employer‟s approval. In case of any item/ product neither covered in this list nor having A BIS specifications, the contractor shall submit the proposed item/ product along-with technical details/ specifications (as per bid), test certificates etc. And other credentials of the manufacturer for Employers approval. 136

LIST OF APPROVED MAKES FOR PRODUCTS AND MATERIALS FOR PLUMBING AND SANITORY RELATED ELECTRICAL WORKS ARE INDICATED IN THE TABLE BELOW. HOWEVER, ANY OTHER MAKE WHICH IS EQUIVALENT AND MEETING THE TENDER SPECIFICATIONS ARE ALSO ACCEPTABLEWITH PRIOR APPROVAL OF THE ENGINEER

4.1.1.1 This specification covers the general requirements of design, preparation of detailed drawings, supply of material, manufacture, testing, inspection at BIDDER‟S works, packing, forwarding, transportation, transit insurance, delivery at site, erection / installation, testing, commissioning at site and carrying out performance / acceptance tests of the equipment, materials and services as per enclosed data sheets and other documents for fire protection system (FPS). 4.1.1.2 The scope of work is as listed below. Sprinkler system, Hydrant system and Portable Fire Extinguishers shall be provided for various floors as per architectural floor plans. Bidder shall note that in areas where gap between false ceiling & ceiling slab exceeds 800 mm, sprinklers shall be provided. 4.1.1.3 Tentative layout drawings for fire water pump house and hydrant systems have been prepared by the PROJECT MANAGER and enclosed with this enquiry. However the following shall be in the scope of bidder. a) Preparation and submission of detailed engineering drawings based on these specifications and latest base drawings. b) Performing and submitting Hydraulic calculations for the entire fireProtection system including sprinkler and hydrant system. c) Drawing(s) showing layout of portable extinguishers along with necessary calculations. d) Preparation of any specific fabrication drawings, as required. e) Obtaining approval of the system from client‟s insurance company, local authority(ies) having jurisdiction (Fire officer, Factory Inspector, etc.) and approving agency appointed by client, including taking out necessary number of prints of drawings, submission to approving agency, co-coordinating site visits, making any minor modification in drawings for the purpose, etc. f) Prepare and submit as-built drawings as per Document and drawing submission & distribution schedule. g) The specification covers Details of pumping and pipe mains for the water based systems. Main fire water pumps, standby pumps, jockey pumps along with their prime movers viz., electric motors and diesel engines. h) Piping inside and around pump house including suction and delivery piping, delivery header, recirculation piping. i) All the valves and specialties in above piping. j) Supporting arrangements needed (indoor & outdoor) for the piping, valves and instrumentation mentioned above. k) Hume pipes are as per standard practice to be provided wherever road crossings are shown. l) Wrapping & coating for underground piping. 159

m) Excavation and back filling required for underground piping / outdoor supporting arrangement. n) Supply and application of painting for piping, fitting, valves, equipment, hose cabinets and structural steel and auxiliary steel for supports. o) It is not the intent to specify completely herein all details of design and construction of equipment or materials to be supplied or of services to be rendered. p) However, the equipment, materials and services shall conform in all respects to high standards of engineering design, workmanship and be capable of performing in continuous commercial operation in a manner acceptable to Client / Project Manager who will interpret the meaning of drawings and specifications and shall have the power to reject any work or material which in his judgement are not in full accordance therewith. q) The equipment to be supplied and erected under this specification are detailed in BOQ and these shall be in accordance with Specification and data sheets and the relevant data sheet A of data sheets section. r) Any item which may not have been specifically mentioned herein but are needed to complete the equipment / system shall also be treated as included and the same shall also be furnished and erected, unless otherwise specifically excluded as indicated. 4.1.1.4 The Bidder‟s scope also includes the following: a) Auxiliary steel / supporting steel for supporting the equipment, piping as well as related drilling, welding work, painting of supports etc. b) All kinds of supports as necessary for piping. c) All anchor bolts, nuts, washers and inserts to be embedded in concrete for the equipment and piping. d) Construction of valve chamber in case of underground pipes. e) Hydro testing & Flushing (All necessary equipments, connections & valves shall be in CONTRACTOR‟S scope.) 4.1.1.5 For routing piping, cabling etc. breaking / making of opening in wall, etc. shall be carried out by Contractor at no extra cost. 4.1.1.6 For pipes of fire water system that enter the buildings, the following will be in scope of contractor: If the pipe has to cross the metal cladding, then a correct size opening shall be made in the cladding and after the pipe is installed, the opening shall be sealed both on inside and outside by using proper sealants as approved by engineerin-charge. Where pipe has to cross brick / block work wall, then a correct size opening shall be made in the wall, an appropriate sleeve installed and after the fire water pipe is installed, the opening between fire water pipe and sleeve shall be sealed both on inside and outside by using proper sealants as approved by engineer-incharge.

4.1.2

SPECIFIC REQUIREMENTS / INSTRUCTION TO BIDDERS 160

4.1.3.1 All equipment supplied shall have capacities not less than those specified in the data sheets and necessary test certificates shall be furnished in this regard. Approved makes and type of equipment/ components shall be supplied. The make, type reference of the equipment is subject to EMPLOYER‟s approval. 4.1.3.2 Grouting of all equipment and supports, supply of grounding material such as cement, sand, necessary form work etc. is Bidder‟s responsibility. 4.1.3.3 No Separate payment will be made for necessary structural supports of piping. 4.1.3.4 The quantities of piping & valves, specialties etc. indicated in Schedule of quantities are indicative for the purpose of Bidder‟s guidance and shall not be binding to limit the scope of Contractor‟s work. In case there is any variation (plus or minus) in the quantities actually supplied and installed from the quoted quantities, the price of the same shall be adjusted based on the unit rates furnished by the BIDDER. 4.1.3.5 Bidder shall note that for piping, quantities of fittings like elbows, reducers, fabricated reducers / miters, compression fittings, flanges, nipples etc. are not defined. The price for supply, fabrication and erection of necessary fittings shall be included in the unit rates for respective pipe sizes. The rates for flanges, and hardware like bolts, nuts, washers and gaskets shall be included in prices quoted for pipes, equipment, valves and specialties as applicable. 4.1.3.6 No separate prices are called for painting. Price for supply and application of painting shall be included in the unit prices for piping, valves and equipment, structural steel work as applicable. 4.1.3.7 For pipes, measurement shall be corner to corner after deducting length of valves, specialties, in-line instruments. 4.1.3.8 All charges for inspection, testing, radiography, dye penetrate testing, flushing, cleaning, hydro/air testing, purging with inert gases, commissioning, including consumables required for same shall be included in the unit rate for erection of piping/valves/equipment. 4.1.3.9 Minor civil works like wall opening, chipping of foundation, grouting of foundations shall be carried out at no extra cost. 4.1.3.10 In addition to the scope mentioned in Clause 4.1.1.2 above, the CONTRACTOR shall supply and erect all required temporary pipes, fittings, flanges, valves and specialties and hangers and supports for testing and cleaning operations, as a part of the erection scope of contract for each of the systems listed above. The BIDDER shall consider this requirement while quoting unit prices for erection. 4.1.3.11 The construction of the fire protection system requires all CONTRACTORS to adhere to good daily housekeeping practices. During construction the CONTRACTOR shall every day, keep all work and storage areas used by them free from accumulation of waste materials. Scrap/ rubbish shall be removed from the site to the satisfaction of the client. The CONTRACTOR shall maintain a crew to carry out this function without any additional payment. 4.1.3.12 The contractor shall prepare and submit to the EMPLOYER for approval, final piping bill of materials as actually erected for purpose of reconciliation. 4.1.3.13 The surplus material with the CONTRACTOR for all materials brought by him shall be taken back by the CONTRACTOR except surplus from those materials for which the EMPLOYER has given, in writing, clearance for procurement. 4.1.3.14 All the pipes shall conform to the relevant piping standards. The pipes shall be joined using butt welding to ANSI B 16.25.

161

4.1.3.15 Slings/ wire ropes and other lifting, hoisting or pulling slings used for lifting various loads shall be invariably tested by a test load before carrying out actual erection. 4.1.3.16 The Vendor shall ensure that other utilities/items and aesthetics are not damaged or disturbed due to the installation activities. 4.1.3.17 Caps over concealed sprinklers shall be fitted only after painting of ceiling (by others) is completed. 4.1.3.18 Sprinklers shall be masked off prior to painting. Any painted sprinkler or sprinkler coated with plaster of Paris is to be replaced by CONTRACTOR at no cost to the EMPLOYER. 4.1.3.19 Method of Testing System: The following tests shall be carried out for ensuring that the system and various components meet the system specifications Hydrant piping

 To withstand min. hydro-test at the pressure 1.5 times the max. working pressure i.e. 8.8 x1.5 =13.2 kg/cm2g for two hours (as per clause no. 7.5.6 of TAC manual)  Leak test: system to be tested at maximum operating pressure for functional test at operating pressure for 2 hours after fixing all components.

Fire water pump

Shall be capable of delivering not less than 150 % of rated capacity at a head of not less than 65 % of the rated head

Diesel Engine

Shall be capable of operating continuously on full load at the site elevation for a period of six hours.

Wrapper coating on underground pipes

Holiday testing

Other components As per data sheet / requirements specified. 4.1.3

BIDDER’S PROPOSAL

4.1.4.1 To enable thorough and fast scrutiny of the BIDDER‟s proposal, BIDDER‟s are advised to respond all their technical data in the enquiry by clearly marking out their response, wherever they want to provide additional data and / or they deviate from the specified requirements. In case of full compliance, the enquiry specification and data sheets will remain unaltered. Each data sheets shall be certified by the BIDDER. This requirement is very important. Non compliance of this by the BIDDER may result in their bid being rejected. 4.1.4.2 Bidder shall ensure and cover all his eligible employees deputed on site under ESI act and Provident Fund Act. The contractor shall be liable to honour all labour laws as applicable in the state, also in respect of payment of minimum wages, payment of Provident Fund and ESI contribution, labour licence and any such acts which are not explicitly mentioned in the document but prevailing during the tenure of contract. The contractor should have his separate code number for compliance under ESI act and 162

Provident Fund Act, so as to cover all his eligible employees under the act in the said code number. The contractor shall comply with the provisions of the act, on month to month basis and shall keep the appropriate record required under the act as well as shall submit the copy of compliance to the Employer regularly. 4.1.4.3 BIDDER is advised to quote for the complete scope and partial response will not be entertained. In case of few items which do not directly fall under BIDDER‟s manufacturing range and / or not available from indigenous source, BIDDER should take the responsibility upon them to arrange to procure them and supply to ensure that their proposal is complete in all respects. 4.1.4.4 Ignorance of the site shall not be accepted as basis for any claim for compensation. The submission of the tender by the BIDDER will be construed as evidence that such an examination was made and any later claims / disputes in regard to price quoted shall not be entertained or considered. Bidders may visit the site, if necessary, after getting permission of client. 4.1.4 CODES AND STANDARDS 4.1.5.1 All equipment, systems and works covered under this specification shall comply with all currently applicable statutes, regulations, standards and safety codes in the locality where the equipment will be installed. All equipment and systems shall comply in all respects with requirements of codes and standards as indicated in data sheets of this specification. 4.1.5.2 Other national standards established to be equivalent or superior to the codes and standards specified are also acceptable. The BIDDER shall furnish English translation of all standards specified in this specification. 4.1.5.3 In the event of any conflict between the codes and standards referred to in the specification and the requirements of this specification, the more stringent of this requirement shall govern. 4.1.5.4 All codes and standards referred to in this specification are latest editions of respective codes and standards. 4.1.5 MAINTENANCE REQUIREMENTS 4.1.6.1 In order to carry out preventive maintenance, it should be possible to readily disassemble, repair, and reassemble the equipment system in the shortest period and to attend to any defect by a minimum disassembly. 4.1.6.2 The BIDDER shall confirm that space shown for the equipment is adequate from point of view of access, easy maintenance and for day to day operation. a) All system must have convenient maintenance characteristics including b) Minimum disturbance to production during preventive maintenance. c) Easy access to replacement part which can be installed by personnel with minimum skill. 4.1.6

GUARANTEES AND PERFORMANCE REQUIREMENTS

4.1.7.1 GENERAL The fire protection system shall perform satisfactorily to meet the guarantee requirements specified to the entire satisfaction of the CLIENT / ENGINEER and statutory requirements. 4.1.7.2 NOISE AND VIBRATION 163

a) Amplitude of vibration at bearing of rotating equipment shall conform to ISO: 10816-1. b) Vibration isolators of proven design shall be furnished by the BIDDER for preventing the transmission of vibration from the equipment (fire water pumps, etc.) to the other neighbouring equipment and structure. 4.1.7

PAINTING

4.1.8.1 Painting in the immediate vicinity of any electrical and rotating equipment and / or pipe in service shall not be performed without the prior written approval of the EMPLOYER for the specific structure, equipment, or pipe to be painted. 4.1.8.2 The CONTRACTOR‟s scaffolding shall be erected, maintained and dismantled without damage to structures, machinery, equipment or obstruction to work of other CONTRACTORs. 4.1.8.3 All surfaces such as light gauge / glasses, required for clear visual observation shall be cleaned after paint application. 4.1.8.4 Special care shall be taken to avoid any paints from dropping on the machined moving parts of equipment, name plates or indicator dials of instruments and control valves. Prior to paint application or spraying paint removable adhesive tape shall be used to cover these. 4.1.8.5 On final completion of all work, the CONTRACTOR shall leave the entire premises within the site of his operation clean and free from all rubbish resulting from his painting operation and shall remove any paint or other blemishes caused by him on adjacent walls, windows, equipment and finished surface. 4.1.8.6 All piping shall be painted after hydro test only. 4.1.8.7 The iron and steel surfaces shall be thoroughly cleaned of all rust, scale, grease or oil by manual or power tools and then primer coat shall be applied. 4.1.8.8 The EMPLOYER reserves the right to inspect the cleaning down and painting operations at any stage and if required by EMPLOYER/ ENGINEER unsatisfactory surface preparation or paint application shall be emended at CONTRACTOR‟s expense. 4.1.8.9 On job site, no painting shall be carried out in a dust laden atmosphere or under unsuitable weather conditions viz. when raining or when metal surfaces are damp or when condensation is likely to affect the paint film before it is dry. 4.1.8.10 All the exposed surfaces of equipment and piping shall be painted with 1 coat of zinc chromate primer and 2 coats of synthetic enamel paint. Shade of finish paint shall be as per IS:5 shade 538. Minimum thickness (DFT) of paint shall be as under:a. Primer - 1 coat of Zinc Chromate primer with minimum dry film thickness (DFT) 25 microns per coat. b. Finish - 2 coat of synthetic enamel paint with minimum dry film thickness (DFT) 25 microns per coat. Total DFT 50 microns minimum.

4.1.8

SYSTEM DESCRIPTION

4.1.9.1 Hydrant System The system shall be designed to operate automatically on operation of any of the hydrant valve(s). The system shall be always pressurized and will operate by a set of pumps and related instrumentation and controls. The operation of pumps shall be 164

sequential. The jockey pump shall start and stop to maintain header pressure. In case of operation of hydrant(s), the jockey pump would be unable to maintain the pressure and the pressure drops further. At a lower predetermined pressure the motor driven pump starts. In case motor driven pump fails to start, the pressure continues falling. At a further lower predetermined pressure, the diesel engine driven standby pump shall operate. Stopping of hydrant system pumps shall be manual 4.1.9.2 Sprinkler System The system shall be designed to operate automatically on breaking of any of the sprinkler bulbs. The operation of sprinklers in a particular zone would be indicated on the panel through instruments/appurtenance provided on the alarm valve. The system shall be always pressurised and will operate by a set of pumps and related instrumentation and controls. The operation of pumps shall be sequential. The jockey pump shall start and stop to maintain header pressure. In case of operation of sprinklers, the jockey pump would be unable to maintain the pressure and the pressure drops further. At a lower predetermined pressure the motor driven sprinkler system pump starts. In case motor driven pump fails to start, the pressure continues falling. At a further lower predetermined pressure, the diesel engine driven standby pump shall operate. Stopping of pump shall be manual. 4.1.9.3 Fire Water Pump House and Underground Fire Water Tank a) Fire Water Reservoir shall be of RCC underground type construction in two equal compartments along with an adjacent underground fire water pump house so that the pumps will be operating under positive suction head. Effective capacity required for exclusive use by fire protection system is 200 cubic meters. b) Following Fire Water Pumps shall be provided in the underground pump house. Name Quantity Parameter Electric Motor driven Main Pump - Horizontal Centrifugal type Diesel Engine driven Stand by Fire Pump - Horizontal Centrifugal type Electric Motor Jockey Pump – Horizontal Centrifugal type

01

171 m3/hr @ 8.8 kg/cm2(g)*

01

171 m3/hr @ 8.8 kg/cm2(g)*

01

10.8 m3/hr @ 8.8 kg/cm2(g) *

Pump Power requirement shall be finalised by the contractor. The jockey pump shall be used for make-up of leakages. The start-stop of jockey pump and start of fire water pumps shall be automatic by sensing of falling header pressure by individual pressure switches. A pressure switch shall be provided on header for sensing header pressure low. A pressure gauge shall be provided at discharge of each pump. The system shall be pressurised at 8 kg/cm2(g). Pump shall be installed with pressure switches in the common delivery header for automatic starting in the following tentative sequence: Sr. No.

Description

Set Pressure 165

(in kg/cm2g) 01. Jockey pump – 1 start * 6 02. Jockey pump – 1 stop * 7 03. Main pump-start 5 04. Standby Pump- start 4  * The above settings are indicative and actual parameters will be finalised in the detail engineering phase. In addition to above Signals, Pump “Running” & “Fail To Start” signal shall be provided & necessary Pressure switches shall be envisaged.  Pumps shall be capable of furnishing not less than 150% of rated capacity at a head of not less than 65% of the rated head. The shut-off head shall not exceed 120% of rated head. 4.1.9.4 Portable Fire Extinguishers Portable fire extinguishers for the proposed facilities are included in this package. Portable fire extinguishers shall be provided as per TAC. All the extinguishers should have ISI mark. Certificates to this effect shall be furnished by CONTRACTOR. Spare quantity of 10% of all types shall be provided. 4.1.9

SUMMARY OF DATA TO BE FURNISHED ALONG WITH BID

The BIDDER shall ensure the following documentation are prepared and submitted to EMPLOYER along with the Bid: 4.1.10.1 TECHNICAL BID a) All data sheet from of the tender specification shall be duly filled in. b) Performance curves/rating charts used for selection of equipment for all the systems shall be furnished along with the bid, with the duty points duly marked on them. c) All sheets of bill of quantities duly filled in, signed and stamped. d) Electrical load list indicating rating and quantity. Bidder is not allowed to change the motor rating in the event of order placement 4.1.10.2 DETAILED ENGINEERING DOCUMENTS AFTER LOI a) The detailed engineering documents, hydrant piping layout drawings, Pump house Piping layout drawings etc., Piping calculation and datasheets for the execution of the job. b) Final data sheets. c) Any drawing detailed fabrication drawing which may be necessary for ring bending / fabrication etc. d) Any drawing which may be required to be modified / generated to suit the site condition / obtaining TAC approval. e) General arrangement drawings for hydrants, pumps, diesel tank valves & specialties. 4.1.10.3 FINAL DOCUMENTS a) Operation and maintenance manuals. b) Quality assurance documentation specific for the project. c) Final as built documentation folder containing all drawings and technical data sheets for future reference.

166

4.1.10 SCHEDULE OF INSPECTION / TESTING AT SITE (TO BE WITNESSED BY CLIENT) 4.1.12.1 The schedule of tests indicated below is indicative and not exhaustive. CONTRACTOR to carry out any other tests at site as per directions of CLIENT. Sl No.

Name of the System/Equipment

Tests to be carried out at site

a)

Pumps

Performance Test

b)

All rotating equipment

Noise level measurement

c)

Power consumption

For all equipment

d)

Pump control panel and logic

Operation test

e)

Piping (Sample)

Hydrostatic leak test, Wrapper coating thickness, Radiography

f)

Fire Hydrant (Sample)

Operation test

g)

Sprinkler

Operation and performance test

h)

Alarm Valve / Installation Control Valve

Operation Test

i)

Fire Extinguisher

Operation Test

and

vibration

level

4.2 FIRE PROTECTION SYSTEM-ELECTRICAL REQUIREMENTS 4.2.1 SCOPE OF WORK 4.2.1.1. Power and Control cabling from MCC to Fire Protection motors including cable

steel for the same is in Contractor‟s scope. 4.2.3.2. LPBS shall be metal enclosed, weather proof, dust and vermin-proof, suitable for

mounting on wall or structures. The enclosure shall be sheet steel, 2 mm thickness and shall have degree of protection not less than IP55. The enclosure shall be painted with one coat of epoxy primer and two coats of Epoxy Light Gray paint – 631 shade as per IS-5. 4.2.3.3. LPBS for shall be provided with 1no. recessed type start push button and 1No. Palm

push, mushroom head type stop push button. 4.2.3.4. All push buttons shall be fitted with two (2) NO and two (2) NC contacts, rated for

continuity bonds shall be provided. 4.2.4 CABLING SYSTEM 4.2.4.1. For MCC, Power supply will be made available at incomer with the help of 1.1 kV,

XLPE Power Cables by others. Further Power and control cabling from MCC to motors shall be in the in scope of Contractor. Incoming Cable sizes will be indicated to successful bidder during execution based on total load of each plant. 4.2.4.2. FPS MCC shall be installed in Pump House. 4.2.4.3. MCC shall be provided with Top Cable entry. Anchor Fasteners, Bolts and other

earthing upto earthing bus shall be in the scope of Bidder. 4.2.5.2. Earthing shall be of GI. 4.2.5.3. Earthing connection at equipment shall be of bolted type. 4.2.5.4. 1 Run of 50x10mm GI Strip shall be provided by contractor along Cable Tray and

shall be connected at suitable point to Earth Grid. 4.2.5.5. Bidder shall furnish the Earthing layout along with calculations (below as well as

4.2.7 TERMINAL POINTS (BATTERY LIMIT) 4.2.7.1. 415 Volts, 50 Hz, TPN supply at the incomer of MCC shall be made available by the

Employer. Further distribution of power and derivation of any other voltage shall be in Contractor‟s scope. 4.2.7.2. Termination of incomer and outgoing cables is in scope of contractor. 4.2.7.3. Earthing above ground shall be considered in contractor‟s scope as per clause no.

4.3 FIRE PROTECTION SYSTEM-INSTRUMENTATION AND CONTROL (I&C) SYSTEM REQUIREMENTS 4.3.1 EQUIPMENT & SERVICES TO BE PROVIDED BY THE BIDDER 4.3.1.1. This specification covers the general requirements for design, preparation of detailed

drawings, supply of material, manufacture, testing, inspection at BIDDER‟S works, packing, forwarding, transportation, transit insurance, delivery at site, erection/installation, testing, commissioning at site and carrying out performance / acceptance tests of the Instrumentation & Control System for Fire Protection System as per specifications in this section, enclosed data sheets, drawings and other documents. 4.3.1.2. The following shall be in the scope of the BIDDER: 4.3.1.3. Supply, erection & commissioning of instruments as per P&ID for following systems:

wired Pressure switches to Fire Protection Panel. Panel shall be located in Pump house along with all required accessories as per specification. The cabling required up to Fire Protection panel from instruments is in the BIDDER‟s scope 4.3.1.5. Contractor shall supply & lay the following cables:

171

a) All cables between the field instruments, junction boxes, control panel, MCC & any other equipment with termination & cable gland at both ends along with all cable laying accessories. b) Power supply cables as required for the instruments & panels. 230 V AC power supply shall be made available by Bidder. Bidder shall supply, lay & terminate the power supply cables from that point to the respective system panels for I&C system. Power supply cables for further distribution of power supply within the panel & from panel to field shall be provided by Bidder. c) Cable trays / GI /PVC conduits for all the above cabling. The cable trays in the outdoor areas shall be provided with covers. 4.3.1.6. All erection hardware including structural steel for erection of all field instruments,

cable trays/ GI / PVAC conduits, panels etc. shall be provided by the BIDDER. BIDDER shall supply all necessary erection hardware required for proper installation of the instruments 4.3.1.7. Earthing for all field instruments, panels, PDBs etc. shall be in the scope of

contractor. 4.3.1.8. Bidder's scope of work shall include complete loop checking of all measurement &

Assumptions to cover lack of information are not allowed. Bidder is obliged to obtain reliable information from EMPLOYER/ PROJECT MANAGER.

4.3.1.12.

The compliance with this specification does not relieve the Bidder from his responsibility towards contractual obligations with regard to completeness, satisfactory operation and easy maintenance of the unit

4.3.1.13.

4.3.1.14.

Supply & erection of GI / PVC conduits as required for cabling.

The BIDDER‟s scope of work shall include trial runs, start up, commissioning and process trials of systems covered in this specification.

4.3.1.15.

4.3.2 DESIGN CRITERIA 4.3.2.1. All instruments shall be suitable for use in hot, humid, tropical & dusty climate. 4.3.2.2. Field mounted electrical and electronic instruments shall be weatherproof to IP-65.

All instruments of submersible type if any shall be protected to IP-68. 4.3.2.3. Wherever the service is hazardous, the field transmitters shall be intrinsically safe.

provided in hazardous areas. For intrinsically safe instruments suitable barriers shall be provided in relay control cabinet by BIDDER. 4.3.2.4. All panels, control desks & enclosures shall comply with the requirements of

4.3.2.5. The field junction boxes for indoor application with IP55 and outdoor JB with IP65

shall be provided. 4.3.2.6. All wetted parts shall be of minimum SS 316. However, based on the process

application, suitable superior material shall be provided to match the process. 4.3.2.7. All instruments and control devices located on control panels shall be of miniaturised

design, suitable for modular flush mounting on control panels with front draw out facility and flexible plug-in connections at the rear. 4.3.2.8. The I&C system shall be designed by selecting high-grade components of proven

quality and proper design of system electronics. The system shall be highly reliable with high-integrity and high MTBF system. 4.3.2.9. All instruments, control systems and accessories furnished under this specification

shall be from the latest proven product range of a qualified manufacturer whose successful performance has been established by a considerable record of satisfactory operation in utility power stations. The normal working range of all indicating instruments shall be between 30% and 80% of the full range.

4.3.2.10.

For pressure switches and temperature switches, the set points shall fall within 30% to 70% of the scale range selected.

4.3.2.11.

For level measurement, the maximum of the range will cover the overflow point or six inches from the top of the tank and the minimum of the range will be six inches above the bottom of the tank. Also, the gauge glasses will be stacked with overlap to cover permissive, alarm and trip levels.

4.3.2.12.

The performance of all instruments shall be unaffected for the variation in voltage and frequency of the power supply.

4.3.2.13.

Provision shall be made for external adjustment of span and zero for all instruments for calibration.

4.3.2.14.

All the hardware/software shall be latest and field proven as available in the market.

4.3.2.15.

All requirements of auxiliary equipment for instruments and control devices including thermo wells, resistance elements and transmitters, special wiring and piping accessories, air filter and pressure regulators, condensation pots and all other special devices required for installation in instrument piping and wiring system shall be furnished complete as required for each individual element, instrument or system unless specifically stated otherwise in this specification.

4.3.2.16.

173

Tag numbering philosophy would be uniform for the entire plant. There would be a single, unique tag for a given equipment / signal.

4.3.2.17.

All parts subject to high pressure, temperature or other severe duty shall be of materials and construction suitable for the service conditions and long operating life.

4.3.2.18.

Components of instruments, control devices, accessories, piping etc. which contact with steam, condensate or boiler feed water shall be manufactured from copper free materials which do not react with media at operating parameters.

4.3.2.19.

Instruments for location in outdoor/indoor/air-conditioned areas shall be designed to suit the environmental conditions and shall be suitable for continuous operation in the operating environment without any loss of function or departure from the specification requirements covered under this specification.

4.3.2.20.

The power supply for the instrumentation & control system shall be 24 V DC, unless otherwise specified.

4.3.2.21. 4.3.2.22.

IBR certification wherever applicable shall be provided with the instruments.

For interlock and protections dedicated switches shall be provided. All trip condition shall be preceded by pre warning.

4.3.3 SPECIFIC REQUIREMENTS / INSTRUCTION TO BIDDERS 4.3.4.1. This is a unit rate contract. Price shall be quoted as per the specifications in section.

The quantities of cables, conduits, trays etc. is estimated based on the Plot plan drawing. Bidders are advised to go through the tender document carefully and suggested that clarifications, if any, are obtained from Department before submission of their quotation. 4.3.4.2. The construction of this facility requires that, all BIDDERS adhere to good daily

housekeeping practices. During construction the BIDDER shall every day, keep all work and storage areas used by them free from accumulation of waste materials. Scrap / rubbish shall be removed from the site to the satisfaction of the EMPLOYER. The BIDDER shall maintain a crew to carry out this function without any additional payment. 4.3.4.3. It is not the intent to specify completely herein all details of design and construction

of equipment or materials to be supplied or of services to be rendered. 4.3.4.4. However, the equipment, materials and services shall conform in all respects to high

standards of engineering design, workmanship and be capable of performing in continuous commercial operation in a manner acceptable to EMPLOYER who will interpret the meaning of drawings and specifications and shall have the power to reject any work or material which in his judgement are not in full accordance therewith. 4.3.4.5. Any item which may not have been specifically mentioned herein but are needed to

complete the equipment / system shall also be treated as included and the same shall also be furnished and erected, unless otherwise specifically excluded as indicated. 174

4.3.4.6. To enable thorough and fast scrutiny of the BIDDER's offer, BIDDERS are advised

to respond all their technical data in the enquiry by clearly marking out their response, wherever they want to provide additional data and / or they deviate from the specified requirements. In case of full compliance, the enquiry specification and data sheets will remain unaltered. Each data sheet & write up in specification shall be signed and stamped by the BIDDER. This requirement is very important. Non compliance of this by the BIDDER may result in their bid being rejected. 4.3.4.7. BIDDER is advised to quote for the complete scope and partial response will not be

entertained. In case of few items which do not directly fall under BIDDER‟s manufacturing range and / or not available from indigenous source, BIDDER should take the responsibility upon themselves to arrange to procure them and supply to ensure that their offer is complete in all respects. 4.3.4 CODES AND STANDARDS 4.3.5.1. All equipment, systems and works covered under this specification shall comply with

all currently applicable statutes, regulations, standards and safety codes in the locality where the equipment will be installed. 4.3.5.2. In particular, the following standards are applicable (latest editions)

4.3.5.3. Other national standards established to be equivalent or superior to the codes and

standards specified are also acceptable. The BIDDER shall furnish English translation of all those standards apart from those mentioned in this specification. 4.3.5.4. In the event of any conflict between the codes and standards referred to in the

specification and the requirements of this specification, the more stringent of these requirements shall govern. 4.3.5.5. Unless indicated otherwise, all codes and standards referred to in this enquiry

specification shall be understood to be the latest version on the date of offer made by the Bidder. 4.3.5 MAINTENANCE REQUIREMENTS 4.3.6.1. In order to carry out preventive maintenance, it should be possible to readily

disassemble, repair, reassemble the I&C equipment in the shortest period and to attend to any defect by a minimum disassembly. 4.3.6.2. All system must have convenient maintenance characteristics including :

a) Minimum disturbance to production during preventive maintenance. b) Easy access to replacement part which can be installed by personnel with minimum skill. 4.3.6 I&C SYSTEM CONFIGURATION 4.3.7.1.

SPRINKLER SYSTEM a) Instruments shall be provided for the system as per P&ID & data sheets in as per specification. b) Alarm from these instruments shall be annunciate in Window Annunciator located in Fire Protection Panel.

4.3.7.2.

HYDRANT SYSTEM a) Instruments shall be provided for the system as per P&ID & data sheets in specification. b) Alarm from these instruments shall be annunciate in window Annunciator located in Fire Protection Panel.

4.3.7.3.

JUNCTION BOX a) All the cables shall be wired to Fire Protection Panel through Junction Boxes.

4.3.7.4.

FIRE PROTECTION SYSTEM CONTROL PANEL a) A relay based Fire Protection Panel shall be provided for local operation and monitoring at fire water pump house. The panel shall house the logic of operation and Annunciation of Fire water pumps. Auto manual switches and push buttons 177

will be provided on panel for local operation of pumps. The annunciator shall be microprocessor based, split type with alarm windows mounted on front door and electronic components inside the panel. Potential free contacts shall be wired up to the terminals inside fire protection panel for each of the alarm. The control supply for the panel shall be 24V DC. The panel will be provided with 230V AC from reliable supply from UPS, AC to DC converter in redundant mode will be provided in the panel. 4.3.7.5.

In the auto mode, the pumps shall be started / stopped as per the table given in P&ID.

b) Jockey Pumps 

The jockey pump shall start/stop automatically based on the pressure in the delivery header P&ID. Alarms shall be provided for indication „trip‟ & „failed to operate‟ status of jockey pump.

c) Main Fire Water Pumps 

The main fire water pumps shall start at the pressures in the hydrant header as given in P&ID. If the main fire water pump fails to start, the system pressure will fall further. When the reaches header as given in P&ID, the standby fire water pump shall start automatically.



The main & standby engine driven fire water pumps shall be stopped manually by pushbuttons on the MCC even in the auto mode.



Alarm shall be generated at delivery header pressure as given in P&ID to alert the operator to stop the fire water pump.



Alarms shall be provided for indication of running, trip & failed to operate status of each fire water pump (main & engine driven) and trip & failed to operate status of jockey pump. The potential free contact from pressure switches provided in the discharge of each pump shall be used for indication of „Pump running.



Provision for Potential Free contacts shall be provided in fire Protection Panel for wiring the Pump trip signal of Fire water Pumps to DDC (If any).

d) Manual mode 

In the manual mode, the fire water pumps & jockey pumps shall be started/stopped using pushbuttons provided on the MCC. 178

4.3.7.6.

The control voltage shall be 24 VDC. The power supply (230 V AC) shall be made available in the panel by the bidder from the MCC.

4.3.7.7.

2 nos of level switch shall be considered for Fire Water storage tank which will generate potential free contact for Hi & Low level alarm in relay based Fire Protection Panel.

4.3.7.8.

Level indicator or Gauge shall be considered for fire water storage tank for local monitor purpose.

4.3.7.9.

The cables to be considered are armored cables.

4.3.7.10.

Cables inside Pump house shall be laid over perforated trays.

4.3.7 SPECIFICATION FOR THE ALL THE FIELD INSTRUMENTS SHALL BE AS GIVEN BELOW 4.3.8.1. Pressure Gauges Sr.No

Sufficient float & guide wire to be supplied on single length to cut at site as per requirement.

5.0

Option of counter weight instead of anchoring of guide wire at bottom is decided based on site condition of the Tanks

6.0

Refer follow-up sheets for service and application details.

4.3.8.6. Junction Boxes Sr. No.

Description

Qty.

Employer‟s requirement 183

Sr.

Description

No.

Qty.

Employer‟s requirement

GENERAL 1.

Manufacturer

2.

Model No. FEATURE

3.

Mounting

Wall/ column

4.

No. of terminals

32 (2x16)

5.

Terminal type

Screwed

6.

Terminal size

Suitable for 2.5 sq. mm. wire

7.

Mounting plate

Required

8.

Cable entry

Bottom

9.

Gland plate

Removable

10.

Door

Single lockable door with gasket

11.

Lock & key

Required

12.

Sheet thickness

3 mm

13.

Painting

Inside: glossy white; Outside: RAL 7032

14.

Protection class

Weather proof to IP 65

MATERIAL OF CONSTRUCTION 15.

Enclosure

MS with epoxy painting

16.

Gasket

Neoprene

17.

Cable entry sealing

Fire proof compound

18.

Name plate/ metal tag

Fixed SS304 184

Sr.

Description

Qty.

No. 19.

Installation hardware

Employer‟s requirement Required

4.3.8.7. Power Supply

230 V AC power supply for the I&C system shall be available from UPS. All field instruments/ valves shall operate on 24 V DC power supply. Two-wire field instruments shall be system powered (24 VDC) from the control system. The distribution of power in field, if required for the instruments/valves, shall be through a designated field mounted junction box (with fused terminals). 4.3.8.8. Instrumentation and Control Cables

(a) All instrument cables for control and indication shall be flame retardant, Low smoke (FRLS) and tested in accordance with IEC 60332 Part 3 and Cable design shall be as per EN 50288-7. (b) The basic specification of the conventional cables shall be as follows: Conductor material

-

Tinned copper, with minimum 7 strands

Conductor size

-

1.0 mm2 for signal cable as minimum. 1.5 mm2 for control cable as minimum 1.5 mm² for power cables as minimum Other sizes based on the load requirement

Cables/ cable tray openings in walls and floors or through pipe sleeves from one area to another or one elevation to another will be sealed by a fireproof sealing compound. The fire-proof sealing compound will effectively prevent the spread of fire from the flaming to non-flaming side, in the event of fire. 4.3.8.11.

WIRING

All inter cubical and internal wiring for all panels/ junction boxes/ power distribution boards shall be carried out with 1100V grade, stranded tinned copper conductors with insulation. The minimum size of the stranded copper conductor used for the panel wiring shall be 1.0 mm2 for analog signals and 1.5 mm2 for 24 V DC control commands. For power supply, the conductor size shall be provided as per the load rating (min. 2.5 sq. mm for 230 V AC and 1.5 sq.mm. for 24 V DC). Control & Power wiring shall be segregated and routed in PVC troughs. Different colour wires shall be used for different voltages. Engraved core identification plastic ferrules, marked to correspond with the panelwiring diagram shall be fitted at both ends of each wire. Cross ferruling shall be done. 186

Suitable termination accessories shall be provided for terminating on the terminal strips in junction boxes, consoles, panels, power distribution boards etc. All necessary cable terminating accessories such as removable gland plates, compression glands, supporting clamps and brackets, wiring troughs and gutters, etc. shall be included in the BIDDER‟s scope of supply. Cable entry into the junction boxes, consoles, panels, power distribution boards etc. shall be using double compression Nickel plated brass. Disconnect type terminals with fuses with visual indication of fuse down shall be provided at each digital input & output terminal. Disconnect type terminals shall be provided for all inputs/ outputs to isolate field input and output for maintenance purpose. 4.3.8.13.

RELAYS

All industrial relays used shall have 2 NO + 2 NC contacts. Whenever relays are used (if applicable) to interface process input/outputs, 20% additional relays shall be provided. In addition, 20% spare space shall be provided in panels/junction box to install 20% additional relays or other items in future. 4.3.8.14.

LABELS

All front mounted equipment, as well as equipment mounted inside the panels/junction boxes shall be provided with individual labels with equipment designation engraved. These shall be phenolic overlays (1.6 mm thick) with black background and white lettering and shall be fixed to the panel by stainless steel screws (counter sunk). The panels/junction boxes shall also be provided at the top with a label engraved with the designation. Lettering for panel/control desk/junction box designation shall be 6 mm. The minimum lettering size for instrument/device labels shall be 3mm. The lettering on the labels shall be subject to EMPLOYER'S approval. Labels of internally mounted equipment shall be clearly visible. 187

EARTHING

4.3.8.15.

Each panel, junction box & power distribution board shall be provided with a safety ground bus & system ground bus made of copper securely fixed along the inside base of the panels. These buses shall be typically of 25 mm wide and 6 mm thick of copper. The safety ground bus shall be properly secured to the plant safety earthing. All metallic cases/frames of relays, instruments, other panel mounted equipment shall be connected to the safety ground bus and shields & drain wires of signal/control cables shall be connected to the system ground bus by independent copper wires of not less than 2.5 sq. mm. The system ground bus shall be electrically isolated from AC mains earthing bus. The insulation colour code for earthing wires shall be green with yellow bands.

4.3.8 TENDER EVALUATION The BIDDER shall comply with all systems / parameters wherever they are specified in data sheets of specification. No credit will be given during tender evaluation, if parameters better than those specified are offered by the BIDDER.

4.3.9 SUMMARY OF DATA TO BE FURNISHED ALONG WITH BID AND AFTER PLACEMENT OF ORDER The BIDDER shall ensure the following documentation are prepared and submitted to EMPLOYER for his review / record. Technical Bid

4.3.10.1.

a) Specification, each data sheet & write-up in specification shall be signed / filled and stamped by the BIDDER indicating compliance to the specifications. b) The following drawings/ documents shall be submitted:

a) Operation and maintenance manuals. b) Quality assurance documentation specific for the project. c) Final as built documentation folder containing all items for future reference.

4.3.10 DATA AND DRAWINGS BY BIDDER (AFTER THE AWARD OF CONTRACT) The BIDDER shall submit the following drawings / documents after award of contract. BIDDER shall adhere to the delivery schedule as submitted along with the BID. BIDDER shall also refer to data sheets in Data sheets for list of deliverables to be submitted for various instruments/ panels.

Sl. No.

Details

(a)

PERT/Bar chart for the design, manufacturing, erection, commissioning, trial operation and performance testing of the system offered.

(b)

System Functional Write-up.

(c)

Unpriced purchase order copy for various bought out /sub contracted equipment / services.

(d)

Letter from Sub BIDDER(s) showing order acceptance and adherence to project schedule.

Data sheets & catalogues for all instruments (including panel mounted instruments), installation sketches along with erection bill of quantities for all field mounted instruments and loop diagrams. 189

On the basis of guidelines specified in this specification Bidder shall submit their own testing, installation, commissioning and acceptance procedure. The procedure shall include purpose of test, test definition, results expected and acceptance criteria. 4.3.12.2. Site Acceptance Tests (SAT)

Full integrated site acceptance test shall be performed before hand over of total system to the EMPLOYER. The test shall demonstrate functionality of the entire I&C system supplied & erected by the BIDDER. The BIDDER shall provide all personnel, test facilities, equipment and tools etc. for the same. All test instruments shall have calibration certificates from approved test house, valid for minimum 6 months. A test procedure is required for approval 2 weeks prior to the schedule start. 4.3.12.3. Instrumentation Testing Requirements

a)

b)

Tests on cable 

Check details are in accordance with the specification.



Check for physical damage.



Megger test between each core and armour/sheath.



Continuity check including screen continuity



Terminations in the Panels/ junction boxes/ battery with battery charger supplied & erected by the BIDDER.

It shall be ensured that erection of junction boxes are as per approved layout drawings. Checking for tagging/identifications of all the panels /junction boxes shall be done. Checks for continuity and termination of all power signal 190

& control cables as per approved drawings shall be carried out. All the panels & junction boxes supplied & erected by the BIDDER shall be checked at site by carrying out the following tests:

c)

d)



Visual & Mechanical testing.



Power up tests on battery with battery charger, checking input & output voltages



Checks on incoming voltage and power distribution in the various panels & junction boxes by switching on MCCBs/MCBs one after the other.



Power up tests on the DC power supply system, checking input & output voltage



Tests on electrical installation



Checking of closing, tripping, supervision and interlocking of control devices.



Checking operation of all alarm circuits.

Instrument Calibration. 

The services of factory trained instrumentation technicians, tools and equipment for field calibration of each instrument to its specified accuracy in accordance with the manufacturer‟s specifications and instructions for calibration shall be provided.



Each instrument shall be calibrated at 0 percent, 25 percent, 50 percent, 75 percent and 100 percent of span using test instruments to simulate inputs and read outputs that are rated to an accuracy of at least 4 times greater than the specified accuracy of the instrument being calibrated.



Such test instruments shall have accuracies traceable to the National Bureau of Standards as applicable.



A written report on each instrument in the format required by the Employer shall be provided to the Employer certifying that it has been calibrated to its published specified accuracy. This report shall include a listing of the published specified accuracy and permissible tolerance at each point of calibration. The report shall be certified by the Engineer.

System Validation 

The services of factory trained and field experienced instrumentation engineer(s) shall be provided to validate each system and verify that it is operational and performing its intended functions as per specifications. 191

e)



Each system shall be validated by simulating inputs at the first element in loop (i.e. sensor) of 10 %, 50 % and 90 % of span, or on/off and verifying loop output devices (i.e. indicator, alarm etc.).



During system validation, provisional settings shall be made on levels, pressure, temperature, alarms etc.



Correct operation of controllers shall be verified by observing that the final control element moves in the proper direction to correct the process variable as compared to the set point.



All logic sequences shall be verified to operate in accordance with the specifications.



All defects and malfunctions disclosed by tests shall be corrected immediately. New parts and materials shall be used as required and approved and tests shall be repeated.



A report certifying completion of validation of each instrument system indicating the errors observed during the validation and any provisional settings made to devices shall be provided. The report shall be made in the format required by the Employer and shall be certified by the Employer when he approves it.

Final Operational Testing and Acceptance. 

Upon completion of instrument calibration and system validation, all systems shall be tested under process conditions.



The testing shall include, but not limited to all specified operational modes, taking process variables to their limits (simulated or process) to verify all alarms, failures, interlocks and operational interlocks between systems and/or mechanical equipment.



Any defects or malfunctions shall be immediately corrected using approved methods and materials and the tests shall then be repeated.



Upon completion of final operational testing, a report shall be submitted, indicating that the total control system provided meets all the functional requirements specified herein. This report shall be made in the format required by the Employer. The Employer shall certify this report when he approves it and it shall constitute final acceptance of the control system.

4.3.12.4. Commissioning

a)

Commissioning Procedure shall be carried out in a methodical sequence as follows 192



Start-up,



Initial running,



Operability adjustment,



Stable operation



Final adjustment

b)

The BIDDER shall check the operating conditions of the Plant by constantly monitoring operating data.

c)

The BIDDER shall specify for each discrete part of the Plant the operational data to be recorded and the manner in which the data is to be taken.

d)

All the operating data shall be recorded, evaluated and submitted to the Employer.

4.3.12 SPARE PHILOSOPHY Spare shall include spare parts, special tools and tackles, including tool box, as required for pre-commissioning & commissioning, start-up and interim operation, day-to-day maintenance, any premature failures for the facilities and first one years operation.

4.3.13.1.

a)

Start-up and Commissioning spares

b)

Mandatory spares

c)

One-year operational spares

d)

Special tools and equipments (if required) Following spare philosophy shall be followed for field instrument:

NOTES 1. Additional tests indicated as 'B' in shops inspection requiremets shall also be carried out when it is applicable. 2. pumps shall be capable of furnishing not less than 150% of the rated capacity at a head not less than 65% of the rated head. the shut-off head shall not exceed 120%of the rated head 3. * value / capacity to be indicated by bidder 4. negative tolerance on capacity, head & efficiency is not acceptable. 5. for vertical inline jockey pumps moc shall be as follows:base/adaptor -grey cast iron, impeller / intermediate chamber -AISI-304, shaft-AISI-316 4.4.1.2. SCOPE

This specification covers the general design, materials, construction features, manufacture, shop inspection and testing at manufacturer‟s works and delivery at site of Horizontal Centrifugal Pumps. 4.4.1.3. CODES AND STANDARDS

The design, materials, construction, manufacture, inspection, testing and performance of horizontal centrifugal pumps shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The equipment shall also conform to latest applicable Indian or equivalent standards. Other international standards are also acceptable, if these are established to be equal 196

or superior to the listed standards. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility. 4.4.1.4. DESIGN REQUIREMENTS

a) Pumps of a particular category shall be identical and shall be suitable for parallel operation with equal load division. Components of identical pumps shall be interchangeable. b) Flow rate versus head curve shall have stable and continuously rising characteristics towards the shut-off head. In case of unstable (drooping) characteristics the duty point shall be well away from the unstable region. Besides the actual flow rate versus head curve, curves for minimum and maximum impeller diameters shall also be shown. c) The shut-off head shall be at least 110% of the differential head. d) The required NPSH at duty point shall be at least one (1) metre less than the available NPSH. e) The rating of the pump driver shall be the larger of the following: 

The maximum power required by the pump from zero discharge to run-out discharge at site climatic conditions.



110% of the power required at the duty point at site climatic conditions.

f) The corrosion allowance for pressure parts shall be 3 mm. g) Pumps shall run smooth without undue noise and vibration. Noise level produced individually or collectively shall not exceed 85 dB (A) measured at a distance of 1.86 metres from the source in any direction. The overall vibration level shall be as per zones A and B of ISO 10816-1 h) In case of fire water pumps, pumps and drivers with all the accessories shall meet the requirements of Tariff Advisory Committee (TAC) or any other standard as called for in data sheet A. Pump type shall be as accepted by TAC accredited Agency. 4.4.1.5. CONSTRUCTION FEATURES

a) In addition to static balancing, impeller and balancing drum shall be balanced dynamically at or near the operating speed. b) Pump shall be provided with renewable type casing ring. Pump having capacity 1,000 M3/Hr and above shall be provided with impeller ring in addition to casing ring. The hardness of impeller ring shall be 50 BHN higher than that of casing ring. c) Pump casing shall be provided with drain and vent connection with plugged or valve connection. d) Bearing shall be oil-lubricated or grease-lubricated and shall have a life of 40,000 hours of working. In case of oil-lubricated bearing, constant oil leveller with magnetic drain plug shall be provided. e) Replaceable shaft sleeves shall be provided to protect the shaft where it passes through stuffing box. 197

f) Stuffing box shall be of such design that it can be repacked without removing any part other than the gland and lantern ring. g) Mechanical seals shall be provided if called for in data sheet - A. If required, a flushing line shall be furnished, complete with strainer and orifice, from the pump discharge to the sealing face. When pumping liquid is not suitable for this purpose, a flushing connection shall be provided so that it can be connected to an external source. Auxiliary piping and plan shall be in accordance with appendix D of API 610. h) The allowable loads on the pump nozzles shall be at least twice the values listed in the relevant tables of API 610 without reference to any other criterion. The base plate shall be designed to cater to the above increased loads. i) In addition to accessories listed in data sheet A, any other accessories required for safe and efficient operation of pump shall be provided. j) All incidental piping and valves required for sealing, lubrication and cooling for stuffing box packing and/or bearing of pump shall be furnished by the VENDOR. k) Leakage from the pump shall be led to the nearest surface drain by OTHERS. Pump VENDOR shall provide necessary arrangement like drip tray, base plate drain connection etc. l) All pumps, except for back-pull out type, shall be provided with flexible coupling. Back-pull out type pumps shall be provided with spacer type coupling. m) Coupling guard made of expanded metal and bolted to the base plate shall be furnished for all coupled pumps. n) In addition to accessories listed in data sheet A, any other accessories required for safe and efficient operation of pump shall be provided. o) All incidental piping and valves required for sealing, lubrication and cooling for stuffing box packing and/or bearing of pump shall be furnished by the VENDOR. p) Leakage from the pump shall be led to the nearest surface drain by OTHERS. Pump VENDOR shall provide necessary arrangement like drip tray, base plate drain connection etc. 4.4.1.6. TESTS AND INSPECTION

a) Hydrotest pressure on casing shall be 1.5 times maximum discharge head or twice differential head whichever is higher. (Maximum discharge head = shut-off head + maximum suction head). Unless otherwise stated in data sheet A, the hydrostatic tests on the casing shall be conducted for a minimum duration of 30 minutes. b) The pumps shall be tested as per IS 5120, at rated speed at MANUFACTURER's works to measure capacity, total head, efficiency and power. The negative tolerance on efficiency shall be limited to 2.5% and not 5% as indicated in IS 5120. These tests shall form the basis for acceptance of pumps except for vibration and noise. The pumps shall be tested over the range covering from shutoff head to the maximum flow. The duration of the test shall be minimum one (1) hour. Minimum five (5) readings approximately equidistant shall be taken for plotting the performance curves. 198

c) After installation, the pumps shall be subjected to testing at site also. If the site performance is found not to meet the requirements regarding vibration and noise as specified, the equipment shall be rectified or replaced by the VENDOR, at no extra cost to the EMPLOYER. 4.4.1.7. PERFORMANCE GUARANTEE

a) Performance parameters to be guaranteed by the VENDOR and tolerances permitted shall be as indicated in specification and/or data sheet A. BIDDER shall confirm acceptance of these by indicating values in data sheet B. Pump or any portion thereof is liable for rejection, if it fails to give any of the guaranteed performance parameters. 4.4.2 DATA SHEETS FOR DIESEL ENGINE AND ACCESSORIES 4.4.2.1. DATA SHEET A 1.0

GENERAL Make and model No.

2.0

Nos. Required

1

3.0

Mode of operation

Continuous Duty Type

4.0

Diesel engine type

Radiator cooled

DESIGN DATA 5.0

Site Conditions (a) Maximum ambient temperature

C

37

(b) Relative humidity at maximum ambient temperature

%

80

(c) Altitude above mean seal level (d) Air temperature at the inlet of charge air cooler

Meters C

3 M above MSL *

6.0

Design Fuel Oil

6.1

Designation

High Speed Diesel

6.2

Standard

IS 1460-2005

6.3

Maximum engine speed

6.4

Type of drive between diesel engine and driven equipment

6.5

Maximum noise level

RPM

To Suit Fire Pump Direct/gear/belts/other s

db ( A )

85 at 1.0 M from 199

Eqpt. Outline 6.6

Engine Air Data ( Primary)

*

7.0

SECONDARY COOLING WATER DATA

Not Required

7.1

Designation

7.2

Pressure at EMPLOYER‟s terminal point

7.3

Temperature at EMPLOYER‟s terminal point (max.)

C

7.4

Total hardness

ppm

7.5

Turbidity

ppm

7.6

Chlorides (as CaCO3)

ppm

8.0

Engine starting system

9.0

Period for taking load from start impulse

Kg/cm2 (g )

Seconds

SCOPE OF SUPPLY 10.0

Diesel engine

Yes

11.0

Driven equipment

Yes

12.0

Control panel

Yes

13.0

Fuel Oil system

13.1

Day tank

Yes

13.2

Fan for Radiator

Yes

13.3

Hand operated transfer pump

No

13.4

Flexible hose on suction and discharge of hand operated transfer pump

No

13.5

AC motor driven priming pump with clock timer

*

13.6

* Thermostatic heater 200

13.7

1 X 100 % Duplex filter or 2 x 100 % Simplex filters

13.8

* *

Interconnecting fuel oil piping between engine, duplex filters and day tank with necessary valves, fittings and other specialities 13.9

Interconnecting piping from transfer pump to day tanks and suction piping for transfer pumps together with necessary valves, fittings and other specialities.

Yes – To be led with hood & bird mesh outside Raw/Fire water Pump house building with min. 1 mtr. above the bldg.

18.0

Instrumentation as per write up

Yes

19.0

Base frame for engine and driven equipment

Yes

20.0

Holding down bolts and foundation bolts

Yes

21.0

Coupling between engine and driven equipment

Yes

22.0

Clutch between engine and driven equipment with engaging assembly

No

23.0

Coupling guard for coupling between engine and driven equipment

No

24.0

Painting at shop

Yes

25.0

Maintenance tools and tackles for entire plant

Yes

Construction Features 26.0

Fuel oil day tank capacity ( Cylindrical )

Min. 6 hrs of engine rating

27.0

Air compressors

Not applicable

28.0

Starting battery type

Lead acid/alkali/other/ not applicable/ VRLA maintenance free

29.0

Type of base frame for engine and drive equipment

Mild Steel

Tests 30.0

Shop testing of fully assembled engine

Required

31.0

Final testing of complete diesel engine set plant at site prior to take over by the EMPLOYER

Required/not required

Codes And Standards & Start Up And Essential Spares 32.0

ISO 3046 Refer note 1 202

Notes: 1. The following spare parts which will be adequate to the requirement of one engine shall be supplied with the engine (only one common set for the quantity of engines mentioned in specifications): a) Two sets of fuel filters, elements and seals. b) Two sets of lubricating oil filters, elements and seals. c) Two sets of belts (where used). d) One complete set of engine-joints, gaskets and hoses, e) Two injector nozzles. f)

One complete set of piston rings – for all cylinders of the engine.

g) One inlet valve and one exhaust valve.

2. Starter battery for manual and automatic start of engine (one for each) and one common 2- rate trickle charger & the same should be capable to charge two batteries simultaneously. Battery capacity shall be adequate for ten consecutive starts without recharging with a cold engine under full compression. 3. The capacity of the diesel engine shall be as per IS 12469 for fire water pumping requirements. Necessary calculations along with pump curves shall be submitted to establish the same. 4. * - Bidder to fill 5. Fuel Oil Day Tank capacity mentioned in cl. No. 3.2 of Data sheets document shall be read as 6 hrs. 4.4.2.2. SCOPE

The design, manufacture and performance of Diesel engine shall comply with all currently applicable statutes, regulations and safety codes in the locality where the Equipment will be installed. The equipment shall also conform to the latest applicable Indian/British/USA / ISO Standards. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility. In particular, the equipment shall conform to the latest editions of the standards followed. 4.4.2.4. DESIGN REQUIREMENTS

203

a) DIESEL ENGINE 

The diesel engine shall be radiator cooled and shall be furnished with at least the minimum equipment according to standard practice. The power rating, required auxiliaries, guarantees of fuel consumption, parallel operation, governor performance and torsional vibration shall be in accordance with ISO: 3046.



The engine shall be provided with an exhaust gas turbocharger having a charge air cooler, integral intake air filter and silencer.

b) FUEL OIL SYSTEM 

An overhead „Day‟ tank of about 10hours rated capacity or capacity which meets the Petroleum rules which ever is less shall be installed. The „Day‟ tank shall be provided with a suitable electrical sensing device to signal „low‟ oil level in the tank. A mechanical oil level indicator shall also be provided to indicate low and high levels. This tank shall in particular, conform to the requirements of IS:803 and API:650. A hand operated / motor operated transfer fuel pump with hoses / piping and other accessories shall be provided to transfer fuel oil to the day tank.

Automatic pressure lubrication shall be provided by engine driven gear type pump. The system should be complete with an oil cooler and 1 x 100 % duplex fine-mesh filters or through 2 x 100% capacity individual filters. Differential pressure gauge across the filters or pressure gauges on either side of the filters shall be provided to monitor the cleanliness of the filters.



The oil cooler shall be either air or water cooled and shall be equipped with the necessary bypass to bypass the cooler during start up until the oil temperature reaches the pre requisite value.

A DC motor driven standby lube oil pump shall be provided, if specified, to supply lube oil to the engine and turbo-charger on failure of the engine driven oil pump and/or during coasting down period of the engine.

lube oil intermittently to the engine when the engine is not in operation to keep the system primed with lube oil for remote and quick starting at any instant. A suitable pressure relieve valve protective device shall also be provided. 

For the charge air cooler and lube oil cooler, the air flow to the charge-air cooler shall be thermostatically controlled.

d) ENGINE STARTING SYSTEM 

Starting of the diesel engine shall be either by compressed air or by electric starting system as specified in Data Sheet-A.



Electric Starting System



The electric starting system shall comprise of starter motor, starter batteries and battery charger and all the required instruments and accessories. If automatic starting is specified in Data Sheet, facility shall also be provided for manual starting of the engine. Necessary auto / manual selector switch shall be provided on the diesel engine control panel. Suitable hydro meter shall be provided for testing the specific gravity of the battery electrolyte. A voltmeter should be provided and installed so that the voltage of the batteries may be ascertained.

e) AIR INTAKE AND EXHAUST SYSTEM 

The VENDOR shall provide an air intake filter and silencer (if required). Air will be taken from the diesel engine room.



The exhaust shall consist of an exhaust driven turbocharger with lagged piping interconnecting cylinder head outlets with the turbocharger inlet. Exhaust manifold shall be of fabricated steel and it shall be suitably lagged. Exhaust gas from the turbocharger shall be led through an exhaust gas silencer. The exhaust gas silencer, necessary pipes, adapters, etc. shall be provided by the VENDOR



The exhaust gas pipe shall be led to the atmosphere at a minimum of 3 meters above the building where the diesel engine is installed. The exhaust pipe shall be insulted for personal protection upto a safe height.

f) GOVERNING SYSTEM 

The governor shall be Woodward type EGB-10 or approved equal. The governor characteristics shall comply with the requirements of „Class A 1governing‟ of ISO 3046. 205



The governor shall have the following features :



The governor shall be provided with an electrically operated speeder gear for remote adjustment of generator frequency, suitable for operation on DC voltage indicated in Data Sheet-A.



An overspeed trip mechanism shall be provided to automatically shut off fuel in case the set speed reaches about 110% of rated speed. The values at which the mechanism trips the engine shall be adjustable.

Unless otherwise specified in Data Sheet-A, tripping of the diesel set for a normal shut down will be done manually, by means of push buttons.



It should be possible to shut down the diesel engine either through the local push button on the diesel control panel or through the remote push button. The trip impulse should directly go to the engine shut down device without passing through the local/remote selector switch.



The diesel engine shall be tripped automatically under the following abnormal conditions :

 Over speed of diesel engine set as sensed by over speed trip device.  Low lubricating oil pressure after engine has attained 90% speed.  Incomplete start after a preset time  DC control supply failure  Emergency stop  Generator fault  Any other tripping condition required for the safe operation of the engine. h) CONTROL PANELS 

 One push button for acknowledging the audible alarm(visual indication shall persist)  One push button for resetting the visual indication after the fault has been cleared.  One push button for testing the illuminated transparencies. 

On the occurrence of a fault the audible alarm shall sound and the appropriate window shall light up. The audible alarm will be silenced by pressing the „acknowledge‟ push button. The visual indication shall, however, persist until the relevant fault contact has reset after which the visual indication can be reset by the „rest‟ push button.



After acknowledgement of one trouble by the „acknowledge‟ push button, the alarm circuit shall be ready to operate for another fault. 207



The VENDOR shall provide all the sensing devices at the diesel engine for the above alarms and accessory relays at the control panel. These shall be suitable for operation on ungrounded DC system. The DC supply will be made available at the control panel by the EMPLOYER. Suitable name plates shall be provided for each window.

i) MOTORS Drive motors shall conform to the companion specification data sheets of low voltage induction motor. j) POWER AND CONTROL CABLES The VENDOR shall include in his scope of supply all auxiliary wiring between the diesel engine and control panels. k) INSTRUMENTS FOR ENGINE The following instrumentation shall be provided: Dial type thermometers shall be provided as follows : 

Lube oil outlet temperature from bearing.



Lube oil temperature at lube oil cooler inlet/outlet



Pressure gauges shall be provided as follows :



At the discharge of all auxiliary pumps provided with the diesel engine.



At the lube oil cooler outlet



On air receiver

Differential pressure gauges across lube oil and fuel oil filters or separate pressure gauges on either side of the filter. Pressure switches shall be provided for automatic starting of the DC motor driven standby lube oil pump on low lube oil pressure. Pressure switches shall be provided for lube oil system to give on alarm if the pressure falls below a preset value and subsequently trip the unit when the minimum safe pressure limit has been reached. A thermostat shall be provided at the lube oil outlet from engine bearing for alarm on high oil temperature. Tachogenerator Primary sensing devices, control valves, controller etc. for : 208



Lube oil temperature and pressure



Fuel oil day tank low level

Leads from all the sensing devices and instruments to which the EMPLOYER‟s cables (from the engine to the diesel control panel) will be connected shall be neatly brought to terminal blocks. The terminal block shall be properly identified. l) PIPING, VALVES AND FITTINGS All necessary interconnecting piping, valves and fittings, supports, filters and strainers shall be provided for lube oil, fuel oil and starting air systems. Terminal points shall be as indicated in specifications. The piping shall be designed, fabricated and tested in accordance with ANSI. B 31.1- Pressure piping code or approved equivalent. 4.4.2.5. ITEMS OF GUARANTEED PERFORMANCE

The following items of performance shall be guaranteed by the VENDOR in respect of the diesel engine units and the auxiliaries, when operating under the specified site conditions. 

Net electrical output at engine shaft



Fuel oil consumption at full load



Lubricating oil consumption at full load



10% overload for one hour without overheating or showing signs of undue stress and within specified frequency variation.



Vibration and noise levels



Governor response, overspeed trip and overspeed capability.

The VENDOR shall indicate the standards according to which tolerances on the performance figures will be applicable. 4.4.2.6. SHOP TESTS

The VENDOR shall perform all the following shop tests to ensure that the equipment conforms to the specifications and meets the performance guarantees. a)

Tests on the diesel engine shall include, but not be limited to, the following : 

One (1) hour at 50 % load



One (1) hour at 75 % load 209



Four (4) hours at full load followed by one (1) hour continuous load of 110%.



Specific fuel oil consumption measurement at various loads.



Vibration levels



Noise levels

b) The Vendor shall perform hydraulic tests at 1.5 times the design pressure on all pressure parts. c) Readings shall be recorded at intervals of 15 minutes during the test period of diesel engine. The Vendor shall provide necessary calibrated instruments for the measurement of pressures, temperatures and flow of fuel oil, lubricating oil, jacket water etc, The tests shall be performed in accordance with ISO 3046. d) The VENDOR shall clearly indicate if he is not in a position to carry out any of the above tests. e) Copies of the test certificates and record of tests shall be submitted to the EMPLOYER for approval. f) In the event, the VENDOR cannot perform any or all of the tests mentioned above or the EMPLOYER cannot witness such shop tests if performed by the VENDOR, the VENDOR shall perform all the tests mentioned above at the site subject to EMPLOYER‟S acceptance after installation and during commissioning. 4.4.2.7. PAINTING

a) Machined and finished surfaces shall be protected against formation of rust and corrosion by application of suitable rust inhibitors. b) All steel surfaces which are to be painted shall be thoroughly cleaned, degreased and given one shop coat of primer, prior to assembly. c) All castings shall be sand blasted, degreased and cleaned before painting. 4.4.2.8. COMMISSIONING

The VENDOR shall perform the following tests at site, but not limited to the following to the satisfaction of the EMPLOYER :

Each hose shall have one male half coupling at one end and one female half coupling at the other end. The couplings shall be joined with hosepipe as per the procedure detailed in tac fire protection manual.

2.

For tg hall, boiler house and mill bays of a power plant and basements 15 m long hoses shall be used.

3.

The fire hose as well as coupling shall be isi marked.

4.

Additional tests indicated as 'B' in shops inspection requirements shall also be carried out when it is applicable. .

Sides: CS sheet as per IS 513 or al sheet As per is 737 or al alloy conforming

20 As per shop inspection and . testsand/

And tac guidelines.

To a-8 wp of is 617 or carbon steel Polyester powder coated 7.

Wall bracket: CS as per IS 513 Or ci as per is 210

8. Swivel joint : Leaded Tin

21 .

Bronze gr ltb2 of IS 318

22 .

9.

Hose reel tubing : Reinforced Rubber As per IS 444 or EN - 694

10. Nozzle: gunmetal or nylon or

Approved subvendors

Materials of constrution

6.

Tests and inspection

Or glass filled polypropylene

Or 18 kg/ cm2 for 5 minutes.

23 . 24 . 25 .

Acrolonitrile butadiene styrene (abs)

218

4.4.8 DATA SHEETS FOR PORTABLE FIRE EXTINGUISHERS

Capacity

Standard

Tac guide lines

Floo r

Wal l

Colou mn

Spare refills

Sl. No.

Type

Quantity (As per BOQ) Trolle y

Total

1.

Sand/ water bucket

Mounted

9 lit

2.0 kg

2.2

3.0 kg

2.3

4.5 kg

2.4

Carbon dioxide

2.1

Yes

IS 15683

Yes/no Yes/no

IS 15683

Yes

6.5 kg

Yes/no

9.0 kg

Yes/no

22.5 kg

Yes/no

6 to 7 kg  2 nos.

Yes/no

3.1

9.0 lit

Yes

3.2

50.0 lit

Yes/no

--

--

--

3.3

150.0 lit

Yes/no

--

--

--

2.5 2.6 2.7 2.8

3.4 3.5 3.6

Chemical foam

2.9 --

3.7 3.8

4.1 4.2 4.3 4.4

Mechanical foam

3.9 9.0 lit

IS 15683

Yes

135.0 lit

IS 14951

Yes/no

4.5 219

Remarks

DATA SHEET A

Standard

Tac guide lines

Floo r

Wal l

Colou mn

Trolle y

Mounted Total

4.6 4.7 4.8

5.2 5.3

Soda acid

5.1

9.0 lit

Yes/no

--

50.0 lit

Yes/no

0.5 kg

Yes/no

--

1.0 kg

Yes/no

--

2.0 kg

Yes/no

--

--

--

--

5.4

6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 612 6.13

Abc type dry chemical powder with map-90 powder

6.1

6.0 kg

IS 15683

Yes

--

9.0 kg

IS 15683

Yes

--

1.0 kg

Yes/no

--

2.0 kg

Yes/no

--

5.0 kg

Yes/no

--

10.0 kg

Yes/no

--

25.0 kg

IS 10658

Yes

--

--

--

50.0 kg

Yes/no

--

--

--

75.0 kg

Yes/no

--

--

--

6.14 1.25 kg

IS 11108

Yes/no

--

--

7.2

2.5 kg

IS 11108

Yes/no

--

--

7.3

4.0 kg

IS 11108

Yes/no

--

--

5.0 kg

IS 11108

Yes/no

--

--

6.5 kg

IS 11108

Yes/no

--

--

7.4 7.5 7.6

Halon 1211

7.1

7.7 7.8 7.9 220

Remarks

Capacity

Spare refills

Sl. No.

Type

Quantity (As per BOQ)

Standard

Tac guide lines

Floo r

Wal l

Colou mn

Trolle y

8.2 8.3 8.4

9.0 lit

IS 15683

Yes

--

Water (gas cartridge)

8.1

Total

Mounted

Remarks

Capacity

Spare refills

Sl. No.

Type

Quantity (As per BOQ)

9.

11.

10.

12.

Approved sub-vendors

Spares and maintenance tools and tackles

8.5

10.1 10.2 10.3 10.4 10.5 10.6

13. 14. 15. 16. 17. 18.

notes 1. 2.

3.

All items conforming to is shall be isi marked. Tests and inspection shall be as per shop inspection and testsand/ applicable indian standards and tac regulations. Additional tests indicated as 'b' in shops inpection requiremets shall also be carried out when it is applicable. Mounting clamps and structural support legs complete with nuts and bolts etc. Shall be provided by the vendor for floor, wall and column mounted portable fire extingushers.

4.4.9 VALVES AND SPECIALITIES GENERAL REQUIREMENTS 4.4.9.1. SCOPE The following paragraphs describe general requirements for valves and specialities. Only the applicable paragraphs for the type of valve or speciality are to be considered along with data sheet-A. These apply unless specified otherwise in data sheet-A. 4.4.9.2. CODES AND STANDARDS Valves and specialities shall be generally as per the following standards: ANSI B16.1

:

Cast Iron Valve Ratings

221

ASME B16.34

:

Ratings of Valves-Flanged, Threaded and Welding Ends

API 594

:

Wafer and Wafer - Lug Check Valves

API 600

:

Steel Flanged and Butt Welding End Gate Valves

API 602

:

Steel Gate Valves, Threaded and Socket Welding Ends

API 609

:

Butterfly Valves

BS 1414

:

Steel Gate Valves, Flanged and Butt Welding Ends

BS 1868

:

Steel Check Valves, Flanged and Butt Welding Ends

BS 1873

:

Steel Globe Valves, Flanged and Butt Welding Ends

BS 5156

:

Diaphragm Valves

BS 5351

:

Steel Ball Valves

BS 5352

:

Steel Gate, Globe and Check Valves, 50 mm and Smaller

IS 778

:

Bronze Valves

MSS-SP 67

:

Butterfly Valves

4.4.9.3. GEAR OPERATORS

Gear operators shall be provided on the following basis: 222

4.4.9.4. GATE AND GLOBE VALVES

Up to and including ANSI 300 class

-

350 mm and larger

600 class and higher

-

200 mm and larger

Plug and ball

-

150 mm and larger

Butterfly

-

200 mm and larger

4.4.9.5. OTHER VALVES

Gear operators shall be suitable for a differential pressure corresponding to the maximum valve rating at room temperature. All gear operators shall be of the enclosed type. 4.4.9.6. INTEGRAL BYPASS

Gate valves shall be provided with integral bypass valve, as per MSS-SP 45, as follows: Classes 150 and 300

-

350 mm and larger

Class 600 and higher

-

200 mm and larger

Type of bypass valve shall generally be the same as the main valve. Bypass pipe shall be at least schedule 80 and material of construction of bypass valve and pipe shall be compatible with the main valve. 4.4.9.7. VALVE STEMS

Valve stems shall be of wrought materials. Castings are not acceptable. 4.4.9.8. BACKSEAT

All gate, globe and piston valves shall be provided with back seating arrangement to facilitate replacement of gland packing with the valve in service. 4.4.9.9. CHECK VALVES

Check valves of sizes 350 mm and larger shall be provided with features to prevent slamming and hammering. These can be in the form of springs or external dash pot. 4.4.9.10.

Strength and leak tests shall be as per any of the standards MSS-SP-61, API 598 or BS EN 12266-1 and 2 at the test pressures indicated in data sheet-A. Stainless steel valves shall be tested using potable water. 4.4.9.14.

NDT REQUIREMENTS

All cast steel valves shall be subject to radiography in all accessible areas, as defined in ASME B16.34, on the following basis: (a)

Class 600 and higher -

All sizes

(b)

Class 300

-

Sizes 450 mm and larger

(c)

Class 150

-

Sizes 600 mm and larger

All cast steel valves of class 600 and higher shall also be subject to magnetic particle or liquid penetrant examination as per ASME B16.34. All cast steel valves of class 300 shall have radiography quality castings irrespective of size. Acceptable levels of defects shall be as per ASME B16.34. 4.4.9.15.

FACE-TO-FACE OR END-TO-END DIMENSIONS

Face-to-face dimensions of flanged-end valves and end-to-end dimensions of butt welding-end valves shall be as per ASME B16.10. For valves not covered by ASME B16.10, the dimensions shall be as per applicable valve standards. 4.4.9.16.

PREPARATION FOR DESPATCH

COATING All carbon steel and cast iron exposed surfaces shall be given one coat of primer and two coats of aluminium finish paint after release has been given for painting and before despatch. Machined surfaces shall be coated with an easily removable rust protective except that this is not applicable for austenitic stainless steel components. END PROTECTION After completion of the requirements of para 14.1, body end ports, flange faces and welding ends shall be covered with suitable close fitting protectors to protect the machined ends and prevent ingress of dirt and moisture. DISC 224

The disc shall be closed before despatch except in the case of soft-seated valves where the disc shall be backed off to relieve the pressure on the seal. PACKING Valves and specialities shall be so packed as to minimise the possibility of damage during storage or transit. The packing shall be suitable for tropical conditions.

As per P & ID Y type Fire water As per detailed engineering 11 Ambient 16 50 1 1 0.5 bar(g) – for strainers on pump suction line 1 bar(g) – for strainers on other locations * * * Four times pipe cross sectional area min No RF As per drawings Flanged 228

30. Notes: 1. General requirements: as per valves and specialities general requirements 2. Additional tests indicated as 'b' in shops inpection requiremets shall also be carried out when it is applicable. 3. '*‟: Bidder to furnish information.

NOTES:1. For general requirements refer valve and specialities. However, in case of overlapping requirements, those of the data sheet a, to be considered as the final one. 2. The valve shall be designed considering the larger of the following torque requirements for which calculations shall be submitted: c) Calculated as per AWWA-C504-80 d) Calculated as per the standard to which valve is designed. 232

3. For manually operated valves, torque required at hand wheel shall not exceed 7 kg.m. 4. Motor operated valve actuator shall be rated to provide an output torque of atleast 150% of torque required as per note-2 above unless otherwise noted. 5. The actuator shall be capable of operating in any mounting angle. 6. The transmission unit shall be designed to transmit twice the valve design torque unless otherwise noted. 7. The actuator shall provide an unseating torque of at least 50% in excess of valve seating torque at the specified voltage unless otherwise noted. 8. Segmental welded carbon steel flange plates above 20 mm thickness shall be subjected to preheating before welding and stress relieving after welding as per is 2825 unless otherwise specified. 9. Unless otherwise specified in specification, one coat of zinc rich primer and two coats of enamel shall be applied to all steel and cast iron exposed surfaces. The minimum thickness of coating shall be 100 microns. 10. The vendor may also suggest any additional spares and tools required for the successful operation, start up and maintainence of the valve. 11. In the absence of any test related data, the relevant testing standard for butterfly valves may be indicated. 4.4.9.22.

AIR RELEASE VALVE

Air release valve shall be 15mm screwed inlet Brass single acting type and shall be fixed on all high points in the system (wet riser) with ball valves or as shown on drawings, suitable for pressure not less than 15 Kg/Sq.cm

Notes: Additional tests indicated as 'B' in shops inpection requiremets shall also be carried out when it is applicable.

1.

*

Also be carried out when these are applicable. bidder shall submit the drawing and the same shall be revised to incorporate the comments of client / Project Manager before being released for construction.

236

4.4.11.1.

SCOPE

This specification covers the general design, materials, manufacture, shop inspection and testing at manufacturer‟s works, delivery at site, handling at site, erection, testing, commissioning, performance testing and handing over of fire water piping and accessories. 4.4.11.2.

CODES AND STANDARDS

The design, materials, manufacture, erection, inspection, testing and performance of fire water piping and accessories shall comply with all the currently applicable statutes, regulations and safety codes in the locality where it is to be installed. The piping shall also conform to the currently applicable Indian and international codes and standards. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility 4.4.11.3.

DESIGN AND GENERAL REQUIREMENTS

a) All pipes, fittings, flanges, valves and specialities etc. shall conform to the enclosed piping material specifications. b) Piping design and layout shall satisfy the requirements of applicable section of ASME B31, Tariff Advisory Committee (TAC), other applicable codes and statutory regulations. c) Piping shall be routed to avoid interference. If interference is noticed at site, piping shall be suitably modified and rectified by the CONTRACTOR at no extra cost to the EMPLOYER. d) All high points in the piping system shall be provided with vents with valves and low points with drains with valves. e) Top of buried piping shall not be less than one (1) metre below the ground level. Buried piping shall be provided with underground protection as per the enclosed specification and requirements of TAC. Valves in buried piping shall be provided with valve chambers with covers. At road crossings buried piping shall run through Hume pipes. Diameter of Hume pipes shall be at least equal to two (2) times the diameter of fire water pipe. Hume pipe shall extend at least 300 mm beyond the road. f) Supports for above ground piping shall follow good engineering practice, requirements of TAC and statutory regulations. Structural steel for pipe supports and other requirements shall conform to IS 2062 grade A. g) For underground piping wherever soil conditions are unsatisfactory, brick masonry or concrete supports shall be provided at regular intervals not exceeding three (3) metres. In case of poor soil conditions, it may be necessary to provide continuous brick masonry or concrete support. The CONTRACTOR shall bring such conditions to the notice of the EMPLOYER and follow his instructions.

237

h) Effective precautions such as capping or sealing shall be taken to protect ends of all pipes, fittings, valves and specialities against ingress of dirt and damage during transit or storage. Flange gasket contact surfaces shall be suitably protected against damage. i)

All piping shall be cleaned and purged with air blast to remove all rust, mill scale etc from inner surface. Rotary wire brush may be used for cleaning pipes of sizes above 300 mm. The method of cleaning shall be such that no material is left on the inner surfaces, which may affect the serviceability of the pipe.

j)

The CONTRACTOR‟S scope for erection under this contract shall include supply of the following: (i)

Joining material as required for all screwed joints and bolts, nuts, studs, washers and gaskets as required for all flanged joints

(iii)

Isotopes for gamma ray, equipment and films for radiography, liquid dye penetrant and other required testing materials and equipment. All these shall be taken back by the CONTRACTOR after completion of work.

(iv)

Erection tools, tackles, scaffolding materials and materials including welding machines, thermocouples, asbestos paper including blankets, cables, temperature recorders and charts and testing equipment, air compressors etc. All these shall be taken back by the CONTRACTOR after completion of work.

k) For general welding requirements refer enclosed specification. The CONTRACTOR shall be responsible for the quality of welding carried out and shall conduct tests to determine the suitability of the welding procedure used. Tests shall be conducted in accordance with codes specified. The results and specimens from qualification tests and operator tests shall be made available to the EMPLOYER. Only qualified welders shall be used and the CONTRACTOR shall inform the EMPLOYER the names of the welders and their experience for approval. A welding procedure qualification shall be submitted to the EMPLOYER for approval before commencement of work. l)

All surplus materials from those supplied by the CONTRACTOR shall be taken back by the CONTRACTOR.

m) All pipes and fittings shall be tested hydrostatically at the shops where manufactured, to test pressures which are given in the respective codes and standards. All piping systems shall be tested hydrostatically after erection to specified test pressure. The test duration shall be two (2) hours or until all joints are examined, whichever is longer. In case of leakage, re-test shall be carried out for the same duration after rectification of defects. 238

n) At least 10% of all the butt-welded joints on hydrant mains shall be radiographically tested and half of the joints radiographed shall be field joints. Acceptable levels of defects shall be as per the applicable code. o) For hydrostatic testing and water flushing, the CONTRACTOR shall furnish necessary tanks, pumps, compressors, other equipment, instruments, piping and supports etc. The EMPLOYER may provide water at one point of supply to which the CONTRACTOR‟S temporary piping shall be connected. All temporary equipment, piping and supports shall be dismantled and taken back by the CONTRACTOR after completion of testing and flushing operation. 4.4.11.4.

EXCAVATION AND BACK FILLING

a) The CONTRACTOR shall carry out necessary civil works associated with buried piping such as excavation, de-watering, back-filling, levelling and compacting. During excavation, large stones and rubbles shall be segregated and removed from the excavated soil and stacked separately. The material from excavation shall be deposited on either side of the trench leaving adequate clear distance from the edges of the trench. This is necessary to prevent the excavated material or the sides of the trench to slip and to avoid covering the laid pipes, hydrant valves, sluice valves and manhole covers etc. b) All precautions shall be taken during excavation and laying operations to guard against possible damage to any existing structures and pipelines. If rock is encountered, it shall be removed up to 150 mm below the bottom of pipes, fittings, valves and specialities and the space resulting shall be refilled with granular materials and properly consolidated. The excess excavated material shall be carried away from site of works up to a distance as directed by the EMPLOYER. c) In case, during excavation, sub-soil water is encountered, the CONTRACTOR shall provide necessary equipment and labour for de-watering the trenches. The CONTRACTOR shall also make necessary arrangements for the disposal of drained water to nearby storm water drain. In no case shall water be allowed to spread over the adjoining areas. All precautions shall be taken to prevent dirt etc. from entering into pipes, when the pipe laying is not in progress by closing the pipe ends with water tight plugs or other approved methods. Trenches shall be back-filled with selected excavated material only after the successful testing of the piping. Tamping around the pipe shall be done by hand or other hand-operated mechanical means. Back filling shall be done in layers not exceeding 300 mm. Each layer shall be consolidated by watering and ramming. 4.4.11.5.

PAINTING AND CORROSION PROTECTION

a) All exposed piping shall be painted with approved paints. b) Before applying the paints, all surfaces shall be cleaned by sand blasting or rotary wire brushing and by dry air blast. All surfaces shall be free of all dirt, mud, rust, grease, scale, or other foreign material.

239

c) After sand blasting or wire brushing is complete, the surfaces shall be protected so that these do not come in contact with grease, oil, other organic matter or moisture prior to application of primer coating. d) Primer coating shall be carried out as quickly as possible after sand blasting or wire brushing. No sand blasted or wire-brushed surface shall be allowed to remain un- coated overnight. Any clean surface that subsequently rusts shall be re-blasted or re- wire brushed before the application of primer. e) Painting operation shall generally be in line with IS 1477 (Parts 1 and 2) and colour of finish paint shall be fire red shade no. 536 of IS 5. 4.4.11.6.

MEASUREMENTS

a) Above ground and underground pipe lengths shall be measured separately. Pipe length shall be measured along the centre line of the pipe. End-to-end or flange face-to-flange face length of fittings, flanges, valves and specialities shall not be deducted from the pipe length. Unit price for supply of pipe shall include supply of fittings and flanges. Similarly, unit price for erection of pipe shall include erection of fittings and flanges. However, supply and erection of valves and specialities shall be considered separately as per para 6.6 below. b) Unit prices for supply and erection of above ground and underground pipes shall also include supply and erection of all piping support items, auxiliary steel and accessories like shoes, saddles, base plates, clamps, bolts and nuts etc. c) Unit prices for supply and erection of above ground pipes shall also include supply of all surface preparation and painting materials and application of painting. d) Unit prices for supply and erection of underground pipes shall also include supply of all surface preparation and wrapping and coating materials required and application of underground protection. e) For valves and specialities the BIDDER shall quote unit price for supply and unit price for erection of each type and size of valve and speciality. f) Non-destructive testing like radiography and die penetrant tests etc. shall be included in the unit price for erection of pipe. No separate charges are payable on this account. g) For concrete pedestals for support of above ground pipes, the BIDDER shall quote unit price for erection of each type and size of pedestal. Supply of all materials required for construction of such pedestals shall be included in the unit price. h) For valve chambers for underground pipes, the BIDDER shall quote unit price for erection. Supply of all materials required for construction of such valve chambers, shall be included in the unit price. i)

For excavation and backfilling, the bidder shall quote unit price per M3 for each type of soil indicated in the schedule of prices. Payment shall be made based on the volume arrived at, as given below, irrespective of the width and depth of the trench actually 240

The purpose of this specification is to describe the technical requirements for the application of hot coal-tar enamel and fibre glass wrapping or pipeline wrapping tapes for the protection of external surface of underground carbon steel piping. 4.4.13.2.

GENERAL

a)

The coating shall consist of coal-tar enamel, inner wrap of fibre glass, final outer wrap of enamel-impregnated fibre or enamel-impregnated kraft paper. The primer and the enamel shall be from the same supplier.

b)

Alternatively, if specified in Data Sheet-A, ready-made tapes available for underground protection shall be used. Tape shall be of approved make. The CONTRACTOR shall furnish all the technical information, experience details etc. of the tapes proposed to be used for review.

c)

The two ends of each length of pipe shall be left bare of primer coating and wrapping for a distance of 150 mm from the end to facilitate field welding and subsequent field coating or wrapping.

d)

The supply, application, characteristics of materials and testing requirements shall be strictly as per IS 10221.

e)

Type of coating system based upon the soil resistivity may be selected on the following basis :

If no specific choice is indicated in Data Sheet-A, system 2.5(b) using coal tar coating shall be used.

SURFACE PREPARATION

Pipe surfaces to be provided with underground protection shall be cleaned by shot or sand blasting. The cleaning shall be so carried out that the piping surface is free from mill scale, rust, oil, welding scale and other foreign materials. Primer shall be applied immediately after shot or sand blasting to prevent rust forming. Superficial rust formed shall be removed by wire brushing or by the use of emery paper. If the rust formation is heavy, re-blasting may be necessary. Around field joints, the pipe surfaces may be cleaned by wire brushing prior to the application of anti-corrosive protection. 4.4.13.4.

PRIMER COAT 243

a)

The primer shall be compatible with the grade of enamel used. It shall be thoroughly mixed before using by stirring or by rocking the drum to provide uniformity of material. The primer coat shall be applied over a thoroughly clean and dry surface within three (3) hours of the cleaning operation, and shall be applied preferably immediately with a uniform thickness on the entire surface of the piping using appropriate quantity per unit area of surface as recommended by the manufacturer. The primer coating shall be free of bubbles, globules, drips and runs. Pipes having a longitudinal seam shall be carefully examined to determine that all excess primer has been brushed out of each side of the welding seam. The primer shall be thoroughly dry before the enamel is applied. If ready-made tapes are used, then primer, as suggested by the manufacturer, shall be used.

b)

Freshly-primed pipe shall be handled carefully to prevent damage. The damaged area shall be re-primed before applying enamel/wrapping tapes.

ENAMEL AND WRAPPING MATERIALS FOR COAL TAR ENAMEL APPLICATION

4.4.13.5.

a)

The material to be used for coating and wrapping shall be coal-tar enamel, fibre glass inner wrap, fibre glass or kraft paper outer wrap, all as per IS 10221.

b)

Well-experienced personnel shall be placed in charge of coating and wrapping operations. They shall strictly follow the manufacturer's instructions regarding recommended temperature in the heating kettles and the temperature at which the hot coating is applied to the pipe. Clean dry enamel in lumps not exceeding 35 kg in weight shall be heated slowly in clean kettles to the recommended temperature, and after reaching the required temperature, the heating flame shall be controlled to prevent over-heating. Any enamel heated in excess of manufacturer's specifications shall be discarded. Only batch heating of enamel shall be permitted.

c)

Kettles shall be completely emptied of one batch and cleaned, if necessary, before preparing the next batch of enamel. The enamel shall be stirred continuously with metal agitators. Enamel kettles shall be equipped with indicating or recording thermometers having temperature range from 100 to 350°C. Enamel withdrawn from the kettles shall be strained through a 1.5 mm strainer.

d)

Enamel shall be moisture - and dirt-free at all times prior to and at the time of heating and application. The primed surface shall be dry and clean at all times and the enamel shall be applied not later than three (3) days after the application of primer. Along with the first coat of enamel, a single spiral inner wrap of fibre glass shall be applied overlapping at least 20 mm on pipes upto 250 mm diameter and 25 mm on larger diameter pipes. It shall be ensured that fibre glass impregnates in the first coat. The second coat of enamel and the second outer wrap of enamel-impregnated fibre glass or enamel-impregnated kraft paper shall be applied in the same way and shall conform to Table-10 or 12 of IS 10221. The total thickness of the coating shall not be less than 2.5 mm.

e)

A third coat of enamel and wrapping shall be applied wherever soil resistivity is below 1000 ohm-cm (extremely corrosive). 244

f)

During cold weather, when the pipe surface temperature is below 7°C or during rainy and foggy weather when moisture tends to collect on the cold pipe, enamelling shall be preceded by warming of the primed pipe. Warming shall be done by any method that will heat the pipe uniformly to the recommended temperature without damage to the primer. Temperature of the pipe shall not exceed 70°C.

g)

Each end of the pipe left bare for welding purpose shall be hand-coated and wrapped after completion of field welding and satisfactory hydrotesting of pipe.

APPLICATIONN OF WRAPPING TAPES

4.4.13.6. a)

After the surface preparation as per para 3.0, the primer shall be applied by brush or spay so as to give a coating thickness is between 2 and 4 mils when wet. The primer shall be allowed to dry to the touch prior to tape application. Primer and tape shall be furnished by the same manufacturer. If application is done in cold weather, the surface of the pipe shall be preheated until it is warm to the touch, and until all traces of moisture are removed and then the primer shall be applied and allowed to dry.

b)

The tape shall be wrapped strictly in accordance with the manufacturer's recommendations in a manner that shall meet the adhesion and holiday detection requirements of IS 10221. There shall be a minimum overlap of 12 mm per single wrap. Each layer of tape shall be of 2 mm thickness.

TESTING

4.4.13.7.

a) THICKNESS i. The thickness of the pipe coating shall be measured either by elcometer or by coating thickness gauge. b) BOND i.

Bond test shall be carried out by cutting 25 mm square at three locations of the coating on a sample test specimen to qualify the procedure. Coating shall be pulled out by lifting one corner of the square. For a good coating, the section shall not peel off easily.

ii.

The coating on the pipe shall be carried out only after satisfactory completion of the qualifying test.

iii.

In case of doubt regarding the quality of coating, bond test shall be carried out on any location of the pipe to the satisfaction of the EMPLOYER. The tests indicated under clauses 7.1 and 7.2 are applicable for coal tar enamel applications only.

c) FIELD ADHESION TEST FOR WRAPPING TAPES i.

Adhesion test shall be made to determine the proper bond between the tape and primed pipe. The temperature of the tape and pipe to be tested shall be between 10 and 27 C. If the temperature is outside this range, hot or cold water shall be poured over the test area until this temperature range is 245

attained. A test area shall be selected by the inspector where the tape is smooth for 15 cm in the longitudinal direction of the tape. Two knife cuts that are 15 cm long and 5 cm apart shall be made through the tape. A flat blade shall be used to pry up 5 cm of the fabric. This 5 cm flap of fabric shall be grasped firmly in one hand and shall be pulled with a quick motion in the direction of the remaining 10 cm of the 15 cm knife cut. ii.

The adhesion is satisfactory if the tape tears at the point of stripping or the fabric strips from the underlying coal tar component, leaving exposed not more than 10% of the primer or metal.

d) HOLIDAY TEST i.

On completion of coating/wrapping, the quality of the coating shall be tested using efficient high voltage holiday detectors, operating at a voltage high enough to jump an air gap, the length of which is equal to the thickness of the coating/wrapping. All holidays found shall be repaired and the repairs shall be retested with the holiday detector to ensure that adequate repairs have been made.

ii.

The suggested test voltage shall be as follows : V

=

1250 (t)½ where

V

=

voltage, in volts

t

=

coating thickness in mils (1 mil = 0.001 in.)

e) CERTIFICATES The CONTRACTOR shall furnish certificates of all the materials purchased by him and also complete instructions from the manufacturer regarding the storage, preparation and application of the coating materials.

Test connection at the remotest nozzle shall be provided. Additional tests indicated as 'B' in shops inpection requiremets shall also be carried out when it is applicable.

2.

4.4.15 WELDING SPECIFICATION FOR EQUIPMENT

SHOP AND SITE FABRICATED

4.4.15.1. SCOPE a)

This specification shall apply to shop and site fabrication of all welded joints in carbon steel, low alloy steel and stainless steel equipment like pressure vessels, tanks, columns and heat exchangers etc.The specification shall apply to all the joints indicated below: i.

Butt joints produced by double sided welding which produce the same quality of deposited weld metal on both inside and outside weld surfaces

ii.

Butt joints produced by single sided welding having backing strip which remains in place and full penetration butt weld without backing strip

iii.

Corner or those joints connecting two (2) members approximately at right angles to each other in the form of L or T

iv.

Partial penetration welds of the groove type which are used for connections not subjected to external loading

v.

Fillet welded joints of approximately triangular cross-section joining two (2) surfaces at approximately right angles to each other and having a throat dimension at least 70% of the thinner of the parts being joined but not less than 6 mm

vi.

Welds attaching nozzles and other connections

vii.

Welds which are used to join non-pressure parts like supports, lugs, brackets, stiffeners and other attachments to the vessel wall

viii.

Any other similar joint which is not specified above but may be encountered during fabrication

4.4.15.2. CODES AND STANDARDS a)

The welding equipment, welding consumables, preheating, Post weld Heat Treatment (PWHT), other auxiliary functions and welding personnel shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment are to be fabricated and installed. Nothing in this specification shall be construed to relieve the VENDOR/CONTRACTOR of this 248

Any other codes and standards specified in Specification or data sheet A of

Testing (ASNT) SNT-TC-IA-

Data sheetsof enquiry specification b)

The codes and standards listed in para 2.1 forms an integral part of this specification. In the event of conflict between this specification and the codes and standards, the more stringent shall govern.

c)

If no specific requirements are given in this specification, the requirements of the applicable code shall govern.

4.4.15.3. WELDING PROCESSES a)

GAS TUNGSTEN ARC WELDING (GTAW) i.

The root pass of single-sided groove welds without backing

ii.

Full penetration nozzle connection where other side is inaccessible

iii.

Any butt and fillet weld on equipment with thickness 5 mm or less

iv.

For all passes of butt and fillet welding of nozzles on equipment and integral piping of size 50 mm NB or smaller

Other processes such as plasma-arc and electro-slag welding may be used only with the approval of the EMPLOYER and depending upon the process and application proposed. These processes may require testing in addition to that specified by the governing procedure qualification code.

f)

Table 1 gives recommendations for welding processes to be used for carbon, low alloy and austenitic stainless steels.

4.4.15.4. WELDING CONSUMABLES a)

The VENDOR/CONTRACTOR shall provide, at no additional cost, all the welding consumables such as electrodes, filler wires, flux, oxygen, acetylene and argon etc., in order to complete the welding in all respects. The consumables shall be from reputed and approved manufacturers. All the consumables shall be approved by the EMPLOYER.

b)

The electrodes and filler wires shall be of the class specified in Table 1 Welding Specification Chart.

c)

Electrode qualification test records shall be submitted for the EMPLOYER's approval. The VENDOR/CONTRACTOR shall also submit batch test certificates from the electrode manufacturer for physical and chemical tests.

d)

Electrodes shall be in sealed containers and adequate care shall be taken for storage, strictly in accordance with the manufacturer‟s recommendations.

e)

Electrodes, which have been removed from the original containers, shall be kept in baking ovens as per the manufacturer‟s recommendations and, once these are taken out, shall be consumed within the time limits stipulated by the manufacturer. Care shall be taken in handling the electrodes to prevent any damage to the flux covering. Portable ovens shall be used for carrying the electrodes from the main oven to the field. Electrodes of different specifications shall be stored in different compartments of a baking oven to avoid mix up.

f)

The electrodes, filler wires and flux used shall be free from contamination such as rust, oil, grease and such foreign matter.

g)

Low hydrogen electrodes shall be used for weld joints in carbon steel if the wall thickness exceeds 19 mm and low alloy steel of all thicknesses except that non- low hydrogen electrodes shall be permitted for the root pass of carbon steel only.

h)

If ultimate tensile strength of base material permits, E 6010 electrodes may be used, for root pass of butt welds and for fillet welds, in carbon steel.

4.4.15.5. WELDING QUALIFICATIONS a)

Qualification of the welding procedures to be used and the performance of welders and welding operators shall conform to the requirements of the BPV Codes and Section IX. For equipment under the purview of IBR, these shall also meet the requirements of IBR. 250

b)

No production welds shall be undertaken until the qualification requirements are completed to the satisfaction of the EMPLOYER.

c)

When impact testing is required by the code or by the specification, these requirements shall be met in qualifying welding procedures.

d)

The VENDOR/CONTRACTOR shall be responsible for qualifying any welding procedure, welders and welding operators intended to be deployed. The VENDOR/CONTRACTOR shall submit the Welding Procedure Specification (WPS) for acceptance by the EMPLOYER. After approval by the EMPLOYER, the procedure qualification test shall be carried out by the VENDOR/CONTRACTOR, at his own expense, duly witnessed by the EMPLOYER. A complete set of test results, in specified format, shall be submitted to the EMPLOYER for approval immediately after successful completion of procedure qualification test. All tests as required by the BPV code Section IX or IBR shall be carried out. The WPS shall require re-qualification, if any of the essential variables or supplementary variables is altered.

e)

Welders and welding operators shall be qualified in accordance with BPV Code and Section IX or IBR, as applicable. The qualification shall be carried out in the presence of the EMPLOYER. Only those welders and welding operators who are qualified by the EMPLOYER shall be deployed on the job. For equipment under the purview of IBR, approval of the local IBR inspector shall be obtained by the VENDOR/CONTRACTOR.

f)

Welders and welding operators shall always keep their identification cards with them and shall produce them on demand. The VENDOR/CONTRACTOR shall issue the identity cards after the same are duly certified by the EMPLOYER. Welder or welding operator, who is not in possession of the identity card, shall not be allowed to work.

g)

The VENDOR/CONTRACTOR shall use forms as per BPV code, section IX, form QW-482, form QW-483 and form QW-484. Other forms are also acceptable subject to approval by the EMPLOYER.

h)

Unless agreed otherwise, the VENDOR/CONTRACTOR shall advise the EMPLOYER, in writing, at least three (3) weeks before any welder or welding operator is deployed on the work, the names and qualifications of the proposed welders, welding operators and welding supervisors. It shall be the VENDOR/CONTRACTOR‟s responsibility to ensure that all welders and welding operators employed by him or his SUB-VENDORS/SUB-CONTRACTORS, on any part of the work either in the VENDOR/CONTRACTOR‟s or his SUBVENDOR/SUB-CONTRACTOR‟s works or at site are fully qualified as required by the code. Each welder and welding operator shall qualify for all types of welds, positions and materials or material combinations he may be called upon to weld.

i)

Should the EMPLOYER require to qualify or requalify any welder or welding operator, the VENDOR/ CONTRACTOR shall make available, at no extra cost to 251

the EMPLOYER the men, equipment and materials for the tests. The cost of testing the welds shall be borne by the VENDOR/CONTRACTOR. j)

Welding supervisors shall have qualifications such as engineering degree or engineering diploma in welding technology with adequate knowledge of welding consumables, welding machines, NDE and a minimum of five (5) years of experience in supervising welding of joints.

k)

All welding, including the tacking up of all welds shall be carried out by qualified welders and welding operators as per approved WPS. Any weld made by other than a qualified welder or welding operator or not carried out as per approved WPS shall be cut out and re-welded.

l)

For purposes of identification and to enable tracing full history of each joint, each welder and welding operator employed on the work shall be given a designation. The welder and welding operator‟s designation and the date on which the joint was made, shall be stamped near the relevant joint and on the relevant drawings also. Copies of the drawings so marked shall be furnished to the EMPLOYER for record purposes. For austenitic stainless steels, welder and welding operator‟s designation shall be applied with water-proof paint or by etching or stencilling machine that is not detrimental to the metal. Alternatively, record cards may be used.

m)

For each welder and welding operator, a record card shall be maintained showing the procedures for which he is qualified. These cards shall note the production welds, the date of the welding done, the type of defects produced and their frequency. The record shall be reviewed once in a week by the EMPLOYER and those welders and welding operators whose work required a disproportionate amount of repair shall be disqualified from welding. Requalification of welders and welding operators disqualified more than three (3) times shall be entirely at the discretion of the EMPLOYER. As far as possible, the qualification shall be carried out at the location (site or shop) where the actual fabrication and welding work is to be carried out.

4.4.15.6. PREPARATION FOR WELDING a)

Surfaces to be welded shall be smooth, uniform and free from fins, tears and other defects, which would adversely affect the quality of the weld. All welding faces and adjoining surfaces, for a distance of at least 50 mm from the edge of the welding groove or 12 mm from the toe of the fillet in the case of socket welded or fillet welded joints, shall be thoroughly cleaned of rust, scale, paint, oil or grease, both inside and outside.

b)

Joints for welding shall be as per the project specifications and approved fabrication drawings.

c)

Butt joints shall be prepared as per ASME BPV Code Section VIII Division 1, unless specified otherwise. For equipment under the purview of IBR, these shall be as per IBR. Any other end preparation which meets the WPS is acceptable. 252

d)

Internal misalignment shall be reduced by trimming but such trimming shall not reduce the finished wall thickness below the required minimum wall thickness. Trimming shall not be abrupt. It shall be tapered with a minimum slope of 1:3. Root opening of the joint shall be within the tolerance limits of the WPS.

e)

Welds shall be as per ASME BPV Code Section VIII Division 1 or in accordance with IBR for equipment under the purview of IBR.

f)

Reinforcing pads and saddles shall have a good fit with the parts to which they are attached. A tell-tale hole shall be provided on the side of any pad or saddle to reveal leakage in the weld and to allow venting during welding and heat treatment. Pad or saddle shall be added, after the branch weld has undergone satisfactory visual and NDE.

g)

The ends shall be prepared by machining, grinding, flame cutting or plasma cutting. Where flame cutting is used, the effect on the mechanical and metallurgical properties of the base metal shall be taken into consideration Flame cutting of alloy steel is not advisable. If alloy steel is cut using flame, the heat affected zone shall be removed completely by grinding and/or machining Magnetic Particle (MT) or Liquid Penetrant (PT) testing shall be carried out to ensure soundness of edges. However, flame cutting of carbon steel is permitted. Wherever practicable, flame cutting shall be carried out by machine. Machine flame-cut edges shall be substantially as smooth and regular as those produced by edge planning and shall be cleaned free of slag. Manual flame cutting shall be permitted only where machine flame cutting is not practicable and with the approval of the EMPLOYER, and such surfaces shall be ground or dressed to a smooth finish as required by the specification and to the satisfaction of the EMPLOYER. Slag, scale or oxides shall be removed by grinding to bright metal at least two (2) mm beyond the burnt area.

h)

Thermal cutting of carbon steel shall be performed under the same conditions of preheating and PWHT as for the welding of each class of material. However, PWHT is not required when:

i)

i.

The heat affected zone produced by thermal cutting is removed by mechanical means immediately after cutting. However, in any case, all remaining slag, scale or oxides shall be removed by grinding to bright metal at least two (2) mm beyond the burnt area, or

ii.

Thermal cutting is part of fabrication, manufacturing or erection sequence leading to a weld end preparation where welding immediately follows. On austenitic stainless steels, plasma cutting, machining or grinding methods shall be used for edge preparation. Flame cutting is not permissible. Cut surfaces shall be machined or ground smooth after plasma cutting. Stainless steel materials shall be ground with Al2O3 grinding wheels and cleaned with stainless steel wire brushes.

253

j)

Before fitting up the weld joint, the profile and dimensions of the weld end preparation shall be checked by the EMPLOYER. If the specified tolerances are exceeded, this shall be corrected (with prior approval) by grinding, machining or any other method acceptable to the EMPLOYER.

k)

Fit-ups shall be examined by the EMPLOYER prior to welding the root pass.

4.4.15.7. TECHNIQUE AND WORKMANSHIP a)

Stainless steel welding shall be carried out at a location away from carbon steel welding.

b)

Components to be welded shall be aligned and spaced as per the requirements of the code and WPS.

c)

Alignment and spacing shall be achieved using suitable wires to maintain the gap. These shall be removed after tack welding. The ends to be welded shall be held using suitable clamps, yokes or other devices which will not damage the surfaces in any manner. It shall be ensured that welding operations do not result in distortions.

d)

Earthing shall be provided on the job using earthing clamps of similar material as the job. Earthing shall not be given through welding rotators.

e)

Tack welds at the root joint, for maintaining joint alignment, shall be made only by qualified welders or welding operators and with filler metal equivalent to that used in the root pass. Tack welds shall be fused with the root pass weld, except that those which have cracked shall be removed. Peening is prohibited on the root and final passes of a weld. The required preheat shall be maintained prior to tack welding. Means shall be made available to measure preheat temperature.

f)

No welding shall be carried out if there is any impingement in the weld area of rain, snow, excessive wind or if the weld area is wet.

g)

Irrespective of the class of steel, root runs shall be made without interruption other than for changing the electrodes or to allow the welder or welding operator to reposition him. Root runs made in the shop may afterwards be allowed to cool by taking suitable precautions to ensure slow cooling e.g. by wrapping in a dry asbestos blanket. Welds made at site shall not be allowed to cool until the thickness of weld metal deposited exceeds one third of the final weld thickness or 10 mm, whichever is greater.

h)

When welding alloy steels, it is strongly recommended that interruption of welding be avoided. Where such interruption is unavoidable, either the preheat shall be maintained during the interruption or the joint shall be post heated or wrapped in dry asbestos blankets to ensure slow cooling. Before recommencing welding, preheat shall be applied again.

i)

Welded-on bridge pieces and temporary attachments shall preferably be avoided. Where approved by the EMPLOYER, these may be used. Material of these shall be compatible with material with which they are temporarily welded. All such 254

pieces shall be removed after welding of joints and the weld area ground flush. These areas shall be subjected to MT and PT examination. These pieces shall be welded by qualified welders and welding operators and with electrodes compatible with the parent material. The preheating requirements of material shall be applied and maintained during the welding of attachments. These temporary attachments shall be removed by grinding, chipping, sawing or by arc or flame gouging. When arc or flame gouging is used, at least three (3) mm of metal shall be left around the surface which shall be removed by grinding. This metal shall not be removed by hammering or by use of force. j)

The arc shall be struck only on those parts of parent metal where weld metal is to be deposited. When inadvertent arc-strikes are made on the base metal surfaces outside the joint groove, the arc-strikes shall be removed by grinding and shall be examined by MT and PT procedures.

k)

Oxides shall not be permitted to form during welding or heat treatment or both, on the internal surfaces which will not be subsequently cleaned. Inert gas purging is an acceptable method to prevent such oxidation. All joints in materials which contain more than 1¼ % chromium shall be purged to assure that less than 1% of oxygen is present on the joint underside before initiation of the welding. The purging operation shall be maintained for a minimum of two (2) passes.

l)

Argon gas used in GTAW process for shielding and purging shall be at least 99.95% pure. Purging shall be carried out at a flow rate depending on diameter until at least five (5) times the volume between dams is displaced. In no case shall the initial purging period be less than 10 minutes. After initial purging, the flow of the backing gas shall be reduced to a point where only a slight positive pressure prevails. Any dams used in purging shall be fully identified and removed after welding and accounted for in order to avoid leaving them in the system. The rate of flow for shielding purposes shall be established in the procedure qualification.

All equipment necessary to carry out the welding, for supporting of the work, for preheating and PWHT including thermal insulation for retaining the heat and for the protection of the welder and welding operator shall be provided by the VENDOR/CONTRACTOR at no extra cost. All necessary precautions shall be taken during cutting and welding operations. It shall be ensured that proper ventilation is available in the welding area and adequate protective gear such as goggles, masks, gloves, protection for the ears and body are used at all times. For guidelines refer ASME standard Z49.1, “Safety in Welding and Cutting”.

o)

After deposition, each layer of weld metal shall be cleaned with a wire brush to remove all slag, scale and defects, to prepare for the proper deposition of the next layer. The material of wire brush shall be compatible with parent material. Stainless steel materials shall be cleaned with grinding wheels or stainless steel brushes which have not been used on other materials. Either aluminium oxide or silicon carbide 255

grinding wheels shall be used. Special care shall be taken to secure complete and thorough penetration of the fusion zone into the bottom of the weld. It is recommended that the root run be checked by MT or PT procedures for critical equipment. p)

If specified, upon completion of welding, the joints shall be wrapped in dry asbestos blankets to ensure slow cooling, unless PWHT is applied immediately.

q)

No welding or welded parts shall be painted, plated, galvanised or heat treated until inspected and approved by the EMPLOYER. Welds shall be prepared and ground in such a way that the weld surfaces merge smoothly into the base metal surface, particularly for welds which are to undergo NDE.

r)

Except where necessary to grind flush for NDE, reinforcement for butt welds may be provided. The height of such reinforcement shall meet the requirements of the code. The reinforcement shall be crowned at the centre and tapered on each side of the joined members. The exposed surface of the weld shall be ground where required to present a workmanlike appearance and shall be free from depressions below the surface of the joined members. The exposed surface of the butt welds shall be free from undercuts, overlaps or abrupt ridges or valleys and shall merge smoothly into the surface at the weld toe.

s)

Repair of weld metal defects shall meet the requirements of the code.

t)

Any weld repair shall be subject to the approval of the EMPLOYER.

u)

In the event of several unsuccessful repair attempts or if the EMPLOYER feels that a satisfactory repair is not feasible, the joint shall be completely remade.

v)

It is preferable to use welding rectifier or DC generator for welding of austenitic steels and while using low hydrogen electrodes.

w)

IDENTIFICATION OF WELDS Wherever code symbol stamps are required on carbon steel and ferritic alloy steel they shall be applied directly on to the member with low stress dotted design metal die stamps or to a small stainless steel plate especially provided for such marks. These plates shall be lightly tack welded using electrodes, of diameter three (3) mm or less, of the type specified for the material. Before making the required tack weld, the material in the immediate surrounding area shall be preheated, as required, by electric means or propane or natural gas burners. Cooling shall take place under asbestos insulation in a draft-free area. Stress relieving of these welds is not required. Steel stamping directly on the surface of alloy steel with other than low stress die stamps shall not be used.

x)

SEAL WELDS i.

Seal welding shall be carried out by qualified welders and welding operators and in accordance with approved drawings. 256

ii.

y)

Threaded joints that are to be seal welded shall be made without the use of thread lubricating compound. Seal weld shall cover all exposed threads. WELD ENCROACHMENT AND MINIMUM DISTANCE BETWEEN WELDS

i.

Welded joints, more specifically longitudinal welds, shall be placed not closer than 50 mm to opening or branch welds, reinforcements, attachment devices or from supports etc. In case of deviation, the EMPLOYER may specify additional NDE.

4.4.15.8. The longitudinal welds of two adjacent components shall be staggered by at least

30o. The minimum distance between welds shall be 50 mm or three (3) times the wall thickness, whichever is greater. Intersection of welds shall be avoided as far as possible. If such welds are present, they shall be subject to suitable NDE at the discretion of the EMPLOYER. 4.4.15.9. PREHEATING a)

Preheating prior to tack welding, welding and thermal cutting shall be used as a means of crack prevention and improving weld reliability. The general requirements of PWHT also apply to preheating.

b)

Preheating shall be used as per the recommendations of ASME BPV Code Section VIII Division 1. For equipment under the purview of IBR, the requirements of IBR shall govern. Preheating of austenitic stainless steels is not required, except at low ambient temperatures, in which case a minimum preheat temperature of 10oC is recommended. Table 2 gives the requirements of preheating for commonly used materials

c)

The preheating zone shall extend 75 mm or a distance equal to four (4) times the material thickness, whichever is greater, beyond the edge of the weld.

d)

The preheat temperature shall be measured at least 75 mm away from the weld preparation.

e)

Where preheating is specified, welding shall continue without interruption. In case interruption cannot be avoided, preheating shall be carried out before recommencement of welding.

f)

Oxy-acetylene preheating shall not be applied.

g)

For preheating, fuel gas/air torches, burner systems (high velocity gas or oil burners) or electrical heating may be used either locally or in a furnace. For preheating above 250oC, electric heating (resistance or inductive heating) is recommended.

h)

Approved temperature - indicating crayons, thermocouples or digital contact or laser pyrometers shall be used to measure preheat and inter-pass temperatures. A calibration report of the pyrometers and thermocouples shall be available. 257

i)

When the preheat temperature is 150oC or higher, the metal shall be maintained at or above the preheat temperature until the weld is completed.

j)

The welding of groove welds in low alloy steels of P-3 to P-5 groups with wall thickness of 19 mm or greater may only be interrupted, provided at least 10 mm of weld metal is deposited, or 25% of the welding groove is filled, whichever is greater. If the welding is interrupted prior to the above, the weld area shall be adequately covered with insulating material to ensure slow cooling. After cooling and before welding is resumed, visual examination of the weld shall be performed to assure that no cracks are formed. Required preheat shall be applied before welding is resumed.

A complete automatic temperature recording shall be made of preheating and stress relieving operations. Where propane gas burners or electrical resistance coils are employed, a complete temperature record of the preheating and stress relieving operation shall be made by means of a box type potentiometer. Other means of recording temperatures are permissible subject to the EMPLOYER's approval.

ii.

Stress relief may be local or full furnace. Local stress relief shall be performed with electric induction or electric resistance coils. Suitable gas burning equipment using natural gas or propane may be employed.

iii.

At no time during a stress relieving/preheating cycle shall any water or liquid cooling medium be employed.

iv.

Where members being joined are unequal in thickness, the dimension of the heavier section shall govern the selection of width of the heated band and the duration of the holding period shall be based on maximum weld thickness.

v.

For local stress relief, using electrical methods, a minimum of two (2) thermocouples tack-welded to the surface and potentiometers shall be used on the part under at least four (4) layers of asbestos paper. The hot junctions of the thermocouples shall be located on either side of the joint at least 12 mm from the edge of the joint but no further away than 100 mm. When employing induction heating, at least six (6) turns of induction cable shall be used on each side of the weld. Induction coils shall be wrapped on top of the asbestos paper protecting the thermocouples with the first turn approximately 150 mm from the centre of the weld. 258

vi.

Local stress employed.

relief using gas torches

or ring burners

may be

However, the procedure shall be limited to small items and shall be approved by the EMPLOYER. vii.

The stress relieving temperature shall be maintained for a period of time proportioned on the basis of one (1) hour per 25 mm of weld thickness at the joint, but in no case less than one (1) hour.

viii.

For piping joints and socket welded joints, pads, bosses, branch welds and couplings, one (1) thermocouple shall be positioned at a minimum distance of two (2) pipe wall thicknesses from the weld.

ix.

Equipment on both sides of any joint shall be adequately supported throughout the preheating, welding and stress relieving operations to prevent distortion.

x.

All heating and cooling rates shall be maintained as per ASME BPV Code and time-temperature charts from the recorder shall be made available for review and acceptance.

xi.

The VENDOR/CONTRACTOR shall submit a detailed written procedure for the PWHT for the approval of the EMPLOYER.

b)

CARBON STEEL i.

Welded joints in carbon steel shall be stress relieved, upon completion of the welding operation, in accordance with Table 3.

ii.

When local stress relief is employed, the welded joint shall be heated to a temperature of not less than 600°C. The temperature level shall be maintained between 600 and 650°C, one (1) hour per 25 mm of weld thickness but in no case less than one (1) hour. The weld area shall then be allowed to cool undisturbed in still air to a temperature not exceeding 315°C.

iii.

Heating and Cooling Carbon steels, after having reached their specific stress relief temperatures, may be cooled in the furnace or under wraps, i.e., leaving the induction coils or resistance heaters and insulation in place. This means that, at the stress relief temperatures, the power to the furnace or heating coils may be shut off and cooling takes place in the furnace or with all insulation and coils remaining on the part. For furnace stress relief, the doors of the furnace may be opened after the power is shut off, at or below 315°C. Thermocouples controlling the temperatures shall remain during the cooling cycle so that excessive cooling, if it occurs, can 259

be observed and immediately corrected. The stress relieving coils and insulation shall only be removed after the part has cooled to below 315°C or if stress relieved in a furnace the part may be removed from the furnace and permitted to cool in still air at a temperature not below 10°C. c)

ALLOY STEEL i.

Welds in alloy steel shall be stress relieved after the welding operation in accordance with Table 3. After welding, the material shall be wrapped in asbestos and allowed to cool slowly if PWHT is not carried out immediately.

ii.

For full furnace stress relief of a welded assembly, the entire fabricated section shall be heated uniformly to the temperature specified. The temperature shall be maintained for a period of time proportioned on the basis of one (1) hour per 25 mm of weld thickness of the piece having the greatest weld thickness in the furnace charge, but in no case, less than one (1) hour.

The specification and size of the electrodes, voltages and amperages, thickness of beads and number of passes shall be as specified in the approved welding procedure or otherwise agreed in writing. Only basic coated electrodes shall be used, which will deposit weld metal having the same or higher physical properties and similar chemical composition to the members being joined. For each batch of approved brand, certificate showing compliance with the specification shall be submitted to the EMPLOYER for review before being released for use. All electrodes shall be purchased in sealed containers and stored properly to prevent deterioration. As welding electrodes deteriorate under adverse conditions of storage leading to dampness in the electrode coating, they shall normally be stored in dehumidified air-conditioned rooms or in hot boxes or ovens in their original sealed containers whose temperatures shall be maintained within specified limits. The condition of electrodes shall be frequently inspected Electrodes with damage to coating shall not be used. Electrodes shall remain identified until consumed. It is preferable to procure low hydrogen electrodes in hermetically sealed containers and preserve them without damage to the containers

(b)

All low hydrogen electrodes, after baking as per the manufacturer‟s recommendations, shall be stored in ovens kept at 80 to 100°C before being used. Recommendations of the electrode manufacturer shall be strictly followed. Until the electrodes are taken out for welding, they shall be stored in portable ovens. The electrodes shall not be exposed to open atmosphere. 260

(c)

For welding of all grades of steel and alloys by the GTAW process, a 2%thoriated tungsten electrode conforming to SFA-5.12-86 EWTh-2 (AWSA5.12-80, EWTh-2) classification shall be used.

(d)

All electrodes to be used on alloy and carbon steel shall conform to ASME BPV Code Section II Part C or any other equivalent code.

(e)

The type of electrodes used shall be only those recommended by the manufacturer for the use in the position in which the welds are to be made.

(f)

Current and polarity shall be maintained as recommended by the electrode manufacturer.

4.4.15.12. INSPECTION AND TESTING (a)

The EMPLOYER shall have free access to inspect welding or any other related operations at any time and at any stage of fabrication.

(b)

The EMPLOYER may require NDE of any weld for reasons other than those given in the specification. The responsibility for the cost of such testing shall be mutually decided between the EMPLOYER and the VENDOR/CONTRACTOR.

(c)

The VENDOR/CONTRACTOR shall inform the EMPLOYER when the weld preparation and set-up for welding of various members selected by the EMPLOYER are in progress so that the EMPLOYER can inspect the assembly before welding starts.

(d)

The responsibilities of the EMPLOYER's representative shall in no way reduce the VENDOR/CONTRACTOR‟s responsibilities to ensure that the work is carried out in accordance with the specificatio

(e)

Any examination by NDE methods shall be performed before or after PWHT based on the applicable code requirements

(f)

For a welded branch connection and for any weld, necessary repairs and NDE shall be completed before any reinforcing pad is added.

4.4.15.13. EXAMINATION OF WELDS (a)

Examination refers to the quality control functions performed by the VENDOR / CONTRACTOR during fabrication, erection and testing.

(b)

As a minimum, the following shall be examined by visual examination: i.

Materials and components to ensure that these are as per the specification and are free from defects. If defects are noticed on “freeissue” items, these shall be brought to the notice of the EMPLOYER without delay.

ii.

Joint preparation and cleanliness

iii.

Fit-up, joint clearance, and internal alignment prior to joining 261

(c)

iv.

Preheating as applicable

v.

Variables specified by the material, position and electrode

vi.

Condition of the root pass after cleaning - external and where accessible, internal

vii.

Slag removal and weld condition between passes

viii.

Appearance of the finished joint and weld dimensions

welding

procedure,

including

filler

Acceptance for the visual examination shall be as per ASME BPV Code Section VIII Division 1 or IBR as applicable.

The VENDOR‟s/CONTRACTOR‟s examining personnel shall have training and experience commensurate with the needs of the specified examinations. NDE supervisors/ examiners shall be qualified at level II or above of ASME BPV Code Section V.

(f)

The VENDOR/CONTRACTOR shall make available to the EMPLOYER copies of certificates of qualification of the examiners he proposes to use for the EMPLOYER‟s approval.

Levels of acceptance of defects in welds shall be in accordance with ASME BPV Code Section VIII Division 1.

(b)

For equipment under the purview of IBR, the levels of acceptable defects shall be as per IBR.

4.4.15.17. REPAIR WELDING (a)

All defects in welds requiring repair shall be removed by flame or arc gouging, grinding, chipping or machining. The major repairs may involve: (i) Cutting through the weld (ii) Cutting out a portion of material containing the weld, or (iii) Removing the weld metal down to the root depending upon the magnitude of the defects. 262

(b)

After removing the defect, the repaired portion and adjacent area shall be examined by the same NDE methods as specified for the original weld and the same acceptance criteria shall hold good.

(c)

All the repair welds shall be made using the same or other specified welding procedures as those used in making the original welds including preheating and stress relieving if originally required. TABLE 1 WELDING SPECIFICATION CHART FOR COMMONLY USED MATERIALS

L. No.

Base material

Welding P. No. process Root

1.0

Filler material Notes Filler

Root

Filler

ER 70S2 OR ER 70S3

ER 70S2 OR ER 70S3

Carbon steels 1

GTAW GTAW

E 6013 F6--EL8 OR E 7018 F7--EL12

1.1

5 mm thick

1.2

5 mm and 19 mm thick

1

GTAW SMAW ER 70S2 OR OR OR ER 70S3 OR SMAW SAW E 6010

1.3

19 mm thk

1

GTAW SMAW ER 70S2 OR OR OR ER 70S3 OR SMAW SAW E 6010

E 7018 F7--EL12

2.0

Low alloy steels

2.1

1¼% cr ½% mo 5 mm thick

4

GTAW GTAW

ER 80S B2

ER 80S B2

2.2

1¼% cr ½% mo 5 mm thick

4

GTAW SMAW ER 80S B2

E 8016 OR E8018-B2

2.3

2¼% cr 1% mo 5 mm thick

5

GTAW GTAW

ER 90S B3

ER 90S B3

2 to 7

2.4

2¼% cr 1% mo 5 mm thick

5

GTAW SMAW ER90S B3

E 9015 OR E 9016 OR E 9018-B3

2 to 7

3.0

Austenitic stainless steels

Type 304 (304l)

8

3.1

GTAW FOR 5 MM THICK ER 308 GTAW SMA (ER 308L) W FOR >5 MM THICK

1

ER 308 (ER 308L) 2 to 7 E 308 (E 308L)

263

3.2

3.3

4.0 4.1

GTAW FOR 5 MM THICK

Type 316 (316l)

8

Type 321

8

Stainless steel to carbon steel SS 304/321

ER 316 (ER 316L)

ER 316 GTAW SMA (ER316L) W FOR >5 MM THICK

2 to 7 E 316 (E 316L)

GTAW FOR 5 MM THICK

ER 321 OR ER 347

ER 321 GTAW OR SMAW ER 347 FOR > 5 MM THICK

2 to 7 E 321 OR E 347

GTAW ER 309 8 to 1 OR SMAW OR SMAW E 309

E 309

E 309 MO

4.2

SS 316

ER 309 GTAW MO 8 to 1 OR SMAW OR SMAW E 309 MO

4.3

SS 304L

GTAW ER 309L 8 to 1 OR SMAW OR SMAW E 309L

E 309L

SS 316L

ER 309 GTAW MOL 8 to 1 OR SMAW OR SMAW E 309 MOL

E 309 MOL

4.4

N NOTES

1.Low hydrogen electrodes shall be used for critical systems such as chlorine, hydrogen, caustic and similar toxic inflammable fluids and also whenever the wall thickness exceeds 19 mm 2. The argon shielding gas flow rate shall not be less than 0.34 M3/Hr. 3. For purging and shielding argon gas shall be used. However, nitrogen may be used as an alternative to argon for purging purpose only. In case of stainless steel, nitrogen may be used where corrosion resistance is not critical. 264

4. For fillet welds, SMAW may be used instead of GTAW for thicknesses above 5 mm. 5. For GTAW, electrode shall be 2% thoriated tungsten. 6. Initial purging prior to welding process shall be a minimum of five (5) times the volume between dams or ten minutes minimum whichever is higher. When welding commences, The purge gas flow shall ensure that the gas pressure is only marginally higher than atmospheric pressure to ensure no root concavity. 7. Back purging using argon/nitrogen shall be maintained for the root run and a minimum of one (1) additional pass. 8. Electrodes and filler wires manufactured by reputed firms duly approved by the EMPLOYER shall only be used. 9. Electrodes shall have at least the same or higher physical properties and similar chemical composition to the members being joined. 10. Read the table in conjunction with para 3.0

NOTES 1. In IBR systems, in carbon steels, PWHT is also required, when the carbon percentage exceeds 0.25%, at the temperature range of 600 +/- 20°C. 2. For all low alloy steel welds under the purview of IBR, the PWHT shall be carried out at the temperature range of 620 to 660° C for 1 1/4% Cr 1/2% Mo steels and at a range of 660 to 750°C for 2 1/4% Cr 1% Mo steels.

266

3. Solution annealing shall be carried out after welding of austenitic stainless steel as per the applicable services. 4. For equipment in carbon steels or alloy steels and meant for lethal service, PWHT of all welds shall be carried out.

4.4.16 LOW VOLTAGE INDUCTION MOTORS 4.4.16.1. SCOPE The specification covers the design, material, constructional features, manufacture, inspection and testing at the VENDOR's / his SUB-VENDOR'S works, delivery to site and performance testing of Low Voltage induction motors rated up to 1000V. 4.4.16.2. CODES AND STANDARDS The design, material, construction, manufacture, inspection, testing and performance of induction motors shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. The equipment shall also conform to the applicable standards specified in data sheet A1 latest revision as on the date of offer. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility. In case of conflict between the standards and this specification, this specification shall govern. 4.4.16.3. DRIVEN EQUIPMENT (a)

When this specification forms part of the driven equipment specification, information not given in the Data Sheet-A will be governed by the driven equipment specification.

(b)

Motors shall be capable of satisfactory operation for the application and duty as specified in the motor Data Sheet-A and as specified for the driven equipment.

4.4.16.4. PERFORMANCE AND CHARACTERISTICS (c)

Motors shall be capable of giving rated output without reduction in the expected life span when operated continuously under either of the following supply conditions as specified in Data Sheet-A. Supply Condition I II (i) Variation in supply voltage from rated voltage +6% +10% (ii)

(ii)

Variation in supply frequency from rated frequency

+3%

+5%

Combined voltage and Frequency variation

9%

10%

(a)

Motors shall be suitable for the method of starting specified in the Data Sheet-A.

(b)

The minimum permissible voltage shall be 85% of the rated voltage during motor starting. 267

(c)

Motors shall be capable of starting and accelerating the load with the applicable method of starting, without winding temperatures reaching injurious levels, when the supply voltage is in the range of 85% of the rated motor voltage to maximum permissible voltage specified in Data Sheet-A.

(d)

The locked rotor current of the motor shall not exceed 600% of full load current (subject to tolerances as per the applicable standard) unless otherwise specified. The locked rotor current of VFD controlled motor shall be within the limit of IS12615 / IEC.

(e)

Motors shall be capable of developing the rated full load torque even if the supply voltage drops to 70% of the rated voltage. The pull out torque of the motor shall be at least 205% of full load torque.

(f)

Motors when started with the driven equipment coupled shall be capable of withstanding at least two successive starts from cold conditions & one start from hot condition without injurious heating of windings. The motors shall also be suitable for three equally spread starts per hour under the above referred supply conditions.

(g)

Motors shall be of Energy Efficient type if specified in Data sheet-A1. Category of Energy efficiency shall be as mentioned in data sheet-A1.

4.4.16.5. SPECIFIC REQUIREMENTS OF VFD DRIVEN MOTORS (a)

The motor shall be suitable for operation with a solid-state power supply consisting of an adjustable frequency inverter for speed control.

(b)

The motor shall be suitable for the current waveforms produced by the power supply including the harmonics generated by the drive.

(c)

The Motor shall be designed to operate continuously at any speed over the range 10100 % of rated speed.

(d)

The permitted voltage variation should take into account the steady state voltage drop across the AC drive and all other system components upstream of the motor.

(e)

The motor shall be constructed to withstand torque pulsations resulting from harmonics generated by the solid-state power supply.

(f)

The driven equipment manufacturer shall be solely responsible for proper selection of the motor for the given load application and the output characteristics of the driven equipment.

4.4.16.6. INSULATION (a)

The insulation shall be given tropical and fungicidal treatment for successful operation of the motor in hot, humid and tropical climate.

(b)

Motors which are VFD controlled shall be inverter grade and shall be suitably derated to take care of reduced cooling at lower speeds. 268

(c)

Insulation of VFD controlled Motors shall be designed to withstand a dv/dt of 0.1 micro sec rise from 10 % to 90 % of steady voltage and a maximum peak of 1600 volts as per NEMA standard MG1 Part 31.40.4.2 .

(d)

The insulation shall be of double coat winding wires which having superior electric strength and thermal capability for VFD controlled motors.

All motor parts exposed directly to atmosphere shall be finished and painted to produce a neat and durable surface which would prevent rusting and corrosion. The equipment shall be thoroughly degreased, all rust, sharp edges and scale removed and treated with one coat of primer and finished with two coats of grey enamel paint.

Two independent earthing points shall be provided on opposite sides of the motor, for bolted connection of the EMPLOYER'S earthing conductors as specified in data sheet-A. These earthing points shall be in addition to earthing stud provided in the terminal box.

(b)

Except when otherwise specified, the motors shall be provided with a bare shaft extension having a key slot and a key at the driving end.

4.4.16.14. TESTS (a)

Motor shall be subjected to all the routine tests as per applicable standard in the presence of the EMPLOYER'S representative. Copies of test certificates of type and routine tests shall be furnished as specified in the distribution schedule, for the EMPLOYER'S approval. The VENDOR shall ensure to use calibrated test equipment/instruments having valid calibration test certificates from standard laboratories traceable to national/international standards.

(b)

If type tests have not been carried out on similar Motors, or if the type test reports submitted are not found in order, then VENDOR shall carry out these tests without any extra cost to the Employer.

4.4.16.15. LOW VOLTAGE INDUCTION MOTORS DATA SHEET-A1 Sl.no .

Description

1.0

General

1.1

Application

(*)

1.2

Numbers required

(*)

1.3

Type of motor

Squirrel cage (energy efficient- IE-3 as per 12615) type

1.4

Supply system fault level

1.5

Type of earthing of supply system neutral

2.0

Rating

2.1

Rated output :

Kw

Kw (*)

2.2

Rated voltage :

V

415v

2.3

Number of phases & frequency

3 phase, 50 hz

2.4

Supply condition as per specification

Ii

2.5

Synchronous speed

3.0

Duty

3.1

Type of duty (clause 9.2 of is:325 or equivalent)

3.2

Power required by load

Unit

Mva

Technical particulars

16KA Effectively earthed system

Rpm

Rpm(*)

(*) Kw

(*) 271

Sl.no .

Description

Unit

Technical particulars

3.3

Energy efficiency class as per is12615-2011

IE3

4.0

Method of starting

D.O.L /STAR DELTA

5.0

Insulation

5.1

Class of insulation

5.2

Ref. Ambient temperature

5.3

Temperature rise by

5.3.1

Thermometer method

5.3.2

By winding resistance method

6.0

Installation

6.1

Location

Indoor

6.2

Hazardous area division (is:5572 or equivalent)

Not applicable

6.3

Atmosphere

Chemical

7.0

Enclosure

7.1

Type of cooling (is 6362)

Tefc

7.2

Designation for degree of protection (is 4691)

Ip 55

8.0

Main terminal box

8.1

Location as seen from non- drive end:

Top/right/left (*)

Ratings

(*)

8.2

(a)

(b)

F with temp. Rise class-b °c

50°c Corresponding to class b insulation

°c

55°c 65°c (class b)

Short time I. Current :

Ka(rms )

Ii. Duration :

Secs.

Dynamic :

Ka (peak)

0.1

8.3

External cable details

(#)

8.3.1

Type

8.3.2

Size & no of cores

8.4

Earthing conductors

8.4.1

Material

Gi

8.4.2

Size

(#) 272

Sl.no . 9.0

Description

Unit

Technical particulars

Miscellaneous requirements

To be filled if motors are bought seperately

9.1

Shaft orientation

Horizontal/vertical/hollow vertical (*)

9.2

Mounting symbol (is:2253 or equivalent)

(*)

9.3

Rotation as seen from non-drive end

Clockwise/anti-clockwise/ bidirectional (*)

9.4

Type of bearing

9.4.1

Drive end

(*)

9.4.2

Non drive end

(*)

9.5

Whether bed plate required

(#)

9.6

Motor shall match the following torque requirements of the driven equipment:

(*)

A)

Starting torue

B)

Full load (rated) torque

C)

Pull out torque

D)

Pull up torque

9.7

Coupling by motor supplier

Yes/no (will be informed later)

9.8

If yes, type of coupling

10.0

Colour shades of paint

Light grey ( shade -631 of is-5)

11

Whether vibration pads required

(#)

12

Temperature detectors/indicators

12.1

Embedded temperature detectors for winding required

No

12.2

Embedded temperature detectors for bearings required

No

12.3

Bearing thermometers for driving end & non driving ends required

No

13

Space heaters for motors required (for motors greater than 30kw )

Yes for motors of 30kw & above

4.4.16.16. LOW VOLTAGE INDUCTION MOTORS DATA SHEET-A2 Sl.no.

Brief title

Reference number of standards

1.

Three phase induction motors

 IS-325

 BS-4999

 IEC-34

2.

Rotating electrical machines

 IS-4722

 BSEN60034-1

 IEC-34-1 273

Sl.no.

Brief title

Reference number of standards

3.

Single phase induction motors

 IS-996

 BS

 IEC

4.

Code of practice for climate proofing

 IS

 BS-6751

 IEC

5.

Designations for types of construction and mounting arrangement of rotating electrical machines

Type of duty and classes of rating assigned to rotating electrical machines

 IS 12824

 BS

 IEC

25. Cbip recommendation for motors NOTES: 1. Details marked thus (*) will be decided and intimated by the bidder based on driven equipment characteristics 2. Data marked thus (#) will be intimated to vendor after placement of order. 3. Data marked thus (^) will be decided and intimated by the bidder. 4. Associated accessories, components/parts, raw material and tests shall in general conform to  is  bs  iec . 5. Offers conforming to other authoritative standards may also be considered/may not be considered. 6. Use  mark for applicable for relavent is and iec.

1 - all stages shall be checked 100 % by vendor and records thereof show n to tce. 2 - witnessing by tce may be 100 % or on random samples. 3 - this document shall be read in conjunction with inspection requirements mentioned in and relevant technical specifications. 4 - the pressure gauges and instruments for measuring critical parameters shall have valid calibration certificate traceable to national laboratory.

3 - this document shall be read in conjunction with inspection requirements mentioned in tce. And relevant technical specifications.

D - a or c, at tce's discretion wherever applicable.

4 - the pressure gauges and instruments for measuring critical parameters shall have valid calibration certificate traceable to national laboratory.

280

281

4.4.17 SHOP INSPECTION AND TESTS 4.4.17.1. SCOPE (a)

This specification covers the requirements for Shop Inspection and Tests to be carried out by the EMPLOYER/PROJECT MANAGER/INSPECTION AGENCY.

4.4.17.2. GENERAL (a)

The plant and equipment covered by the PURCHASE ORDER/CONTRACT shall be subjected to inspection and testing. The VENDOR/CONTRACTOR shall provide all services to establish and maintain quality of workmanship in his works and that of his SUBVENDOR‟s/SUB-CONTRACTOR‟s works to ensure the mechanical accuracy of components, compliance with approved drawings, identification and acceptability of all materials, parts and equipment.

(b)

For supply of systems, the VENDOR/CONTRACTOR shall, at the start of the PURCHASE ORDER/CONTRACT, furnish a total list of items in his scope of work. This list, giving a brief description of the item, quantity, names of probable SUB-VENDORS/SUBCONTRACTORS, and a blank column for agency for final approval of drawings and documents, shall be submitted for approval by EMPLOYER/PROJECT MANAGER. The blank column shall be filled by EMPLOYER/PROJECT MANAGER. The list shall be submitted within two weeks from the date of Letter of Intent.

(c)

For systems and major items such as pressure and load bearing items, machineries etc., the VENDOR/CONTRACTOR shall furnish quality plan giving details of checks and tests to be conducted by them on material, process, sub- assembly and assembly. These shall include requirements as prescribed in the applicable specifications, codes and statutory requirements. The quality plan shall be reviewed by the EMPLOYER/PROJECT MANAGER and the stages to be witnessed and verified shall be indicated by the EMPLOYER/PROJECT MANAGER in the approved quality plan.

(d)

The VENDOR/CONTRACTOR shall give the EMPLOYER/PROJECT MANAGER written notice of any material being ready for testing as per format enclosed. The clear notice period shall be seven (7) days for local inspection and fifteen (15) days for outstation inspection. Such tests shall be to the VENDOR‟s/CONTRACTOR's account except for the expenses of the EMPLOYER/PROJECT MANAGER. The EMPLOYER/PROJECT MANAGER, unless the inspection of the tests is virtually waived, shall fix a date for inspection with the VENDOR/CONTRACTOR and attend such tests within fifteen (15) days of the date on which the equipment is notified as being ready for test and inspection failing which, the VENDOR/CONTRACTOR may proceed with the tests and shall forthwith forward to the EMPLOYER/PROJECT MANAGER duly certified copies of tests in triplicate. If the VENDOR/CONTRACTOR fails to offer the equipment for inspection as per the agreed date, he is liable to pay for the time and expenses for the infructuous visit of the EMPLOYER/PROJECT MANAGER.

(e)

In all cases where inspection and tests are required whether at the premises or works of the VENDOR/CONTRACTOR or of any SUB-VENDOR/SUB- CONTRACTOR or at 281

laboratory, the VENDOR/CONTRACTOR, except where otherwise specified, shall provide free of charge all facilities such as labour, materials, electricity, fuel, water, stores, test bed, apparatus and instruments, laboratory tests etc. as may be required by the EMPLOYER/PROJECT MANAGER to carry out effectively such tests of the equipment in accordance with the PURCHASE ORDER/CONTRACT and shall give facilities to the EMPLOYER/ PROJECT MANAGER to accomplish testing. (f)

The EMPLOYER/PROJECT MANAGER shall at all working hours have access to all parts of the VENDOR‟s/CONTRACTOR's and his SUB-VENDOR‟s/SUB- CONTRACTOR's factory where the items of the plant are being prepared, for carrying out inspection activities as deemed necessary. A set of the relevant latest approved drawings with approval marking of the EMPLOYER/ PROJECT MANAGER and drawings for proprietary items shall be made available by the VENDOR/CONTRACTOR to the EMPLOYER/PROJECT MANAGER, for reference during inspection.

(g)

In the case of stage inspection hold points, the VENDOR/CONTRACTOR shall proceed from one stage to another only after the component is inspected by the EMPLOYER/PROJECT MANAGER and written permission given to proceed further. The same procedure shall be adopted for any rectifications and repairs suggested by the EMPLOYER/PROJECT MANAGER.

(h)

The EMPLOYER/PROJECT MANAGER shall have the right to inspect any machinery, material, structures, equipment or workmanship furnished or used by the VENDOR/CONTRACTOR and may reject any which is defective or unsuitable for the use and purpose intended, or which is not in accordance with the intent of the PURCHASE ORDER/CONTRACT. The VENDOR/ CONTRACTOR, upon demand by the EMPLOYER/PROJECT MANAGER, shall remedy or replace at the VENDOR‟s/CONTRACTOR's expense such defective or unsuitable items of the plant, or the EMPLOYER/PROJECT MANAGER may, at the expense of the VENDOR/CONTRACTOR, remedy or replace such defective or unsuitable items of the Plant.

(i)

All principal mill test reports, the VENDOR/CONTRACTOR inspection and tests reports, test certificates and test curves shall be supplied for all inspection and tests carried out including other records such as stress relieving charts, radiographic charts and other nondestructive testing records in accordance with the provisions of the PURCHASE ORDER/CONTRACT, duly certified by the main VENDOR/CONTRACTOR. The EMPLOYER/PROJECT MANAGER shall reserve the right to call for certificates of origin and test certificates for all raw material and equipment at any stage of manufacture.

(j)

The EMPLOYER/PROJECT MANAGER shall within fifteen (15) days from the date of inspection as defined herein give notice in writing to the VENDOR/ CONTRACTOR of any non-conformance pertaining to all or any equipment and workmanship which in his opinion is not in accordance with the PURCHASE ORDER/CONTRACT. The VENDOR/CONTRACTOR shall give due consideration to such objections and shall either make the modifications that may be necessary to meet the said objections or shall confirm in writing to the EMPLOYER/PROJECT MANAGER giving reasons therein that no modifications are necessary to comply with the PURCHASE ORDER/CONTRACT. 282

(k)

When the factory tests and documentation have been satisfactorily completed at the VENDOR‟s/CONTRACTOR's or SUB-VENDOR's/CONTRACTOR's works, the EMPLOYER/PROJECT MANAGER shall issue acceptance note or shipping release note or a certificate to this effect within fifteen (15) days after completion, but if the tests are not witnessed by the EMPLOYER/ PROJECT MANAGER, the certificate or comments thereof shall be issued within fifteen (15) days of the receipt of the VENDOR‟s/CONTRACTOR's test certificate by the EMPLOYER/PROJECT MANAGER. Failure of the EMPLOYER/ PROJECT MANAGER to take such an action shall not prevent the VENDOR/ CONTRACTOR from proceeding with the work. The completion of these tests or the issue of the certificates shall not bind the EMPLOYER/ PROJECT MANAGER to accept the equipment, should it, on further tests after erection, be found not to comply with the PURCHASE ORDER/CONTRACT.

(l)

None of the plant and the equipment to be furnished or used in connection with the PURCHASE ORDER/CONTRACT shall be despatched until shop inspection, satisfactory to the EMPLOYER/PROJECT MANAGER has been made. However, such shop inspection and/or certification shall not relieve the VENDOR/CONTRACTOR of his responsibility for furnishing the plant and the equipment conforming to the requirements of the PURCHASE ORDER/ CONTRACT nor prejudice any claim, right or privilege which the EMPLOYER/ PROJECT MANAGER may have because of the use of defective or unsatisfactory items. Should the EMPLOYER/PROJECT MANAGER waive the right to inspect any item, such waiver shall not relieve the VENDOR/CONTRACTOR in any way from his obligation under the PURCHASE ORDER/CONTRACT. In the event of the EMPLOYER‟s/PROJECT MANAGER's inspection revealing poor quality of goods, the EMPLOYER/PROJECT MANAGER shall be at liberty to specify additional inspection procedures, if required, to ascertain the VENDOR/CONTRACTOR's compliance with the equipment specifications.

4.4.17.3. SUB-ORDERS AND SUB-CONTRACTS (a)

In order to facilitate the inspection of bought-out materials and plant, the VENDOR/CONTRACTOR shall submit for approval, three (3) copies of all sub- orders and sub-contracts placed by him as soon as these are issued. Copies of any drawings referred to in the sub-order or sub-contracts shall also be submitted, unless agreed otherwise by the EMPLOYER/PROJECT MANAGER.

(b)

The sub-orders, sub-contracts and drawings referred to above shall include all components which are subjected to electrical and mechanical pressure or stress when the plant is in operation, and also auxiliaries and spares which are to be directly despatched to site from the SUB-VENDOR‟s/SUB-CONTRACTOR's works.

(c)

All sub-orders and sub-contracts of the main VENDOR/CONTRACTOR shall clearly be marked with the main VENDOR‟s/CONTRACTOR's name and the EMPLOYER‟s/PROJECT MANAGER‟s name and the PURCHASE ORDER/ CONTRACT reference. These shall include the following statement:

283

The plant or the equipment which is the subject of this PURCHASE ORDER/ CONTRACT shall comply in every respect with the requirements of the EMPLOYER‟s/PROJECT MANAGER's technical specifications and shall be subject to inspection and tests to the satisfaction of the EMPLOYER/PROJECT MANAGER. (d)

For the purpose of this para, it is obligatory on the VENDOR/CONTRACTOR that he advises his SUB-VENDOR/SUB-CONTRACTOR of the pertinent clauses in this specification when ordering bought-out plant, equipment or materials. In particular, the VENDOR/CONTRACTOR shall advise every SUB- VENDOR/SUB-CONTRACTOR that he is required to supply design calculations, drawings, inspection reports and test certificates strictly in accordance with this specification and technical information for inclusion in the Instruction Manual as specified in specification. The SUB-VENDORS/SUBCONTRACTORS should also be reminded that they shall include with their offer all tools and appliances necessary for proper maintenance and all spare parts as per specified in specification. Itemised prices of the recommended spare parts shall be submitted together with the appropriate part numbers and drawings.

(e)

Sub-ordering and sub-contracting for major items such as pressure and load bearing items, machinery etc. can be done only with the approval of the EMPLOYER/PROJECT MANAGER.

4.4.17.4. MATERIAL TESTS (a)

In the event of the EMPLOYER/PROJECT MANAGER being supplied with the certified particulars of tests which have been carried out for the VENDOR/ CONTRACTOR by the supplier of material, the EMPLOYER/PROJECT MANAGER may, at his own discretion, accept the same as proper evidence of compliance with the requirements of appropriate specifications for the materials.

(b)

The VENDOR/CONTRACTOR is to provide test pieces as required by the EMPLOYER/PROJECT MANAGER to enable him to determine the quality of material supplied under the PURCHASE ORDER/CONTRACT. If any test piece fails to comply with the requirements, the EMPLOYER/PROJECT MANAGER may reject the entire lot of material represented by the test piece.

(c)

Critical materials used in manufacture of the equipment and construction of the plant covered by the PURCHASE ORDER/CONTRACT may also be subjected to one or more of the NonDestructive Tests (NDT) as called for in the enquiry document or as mutually agreed. Salvaging of material due to unacceptable defect is to be attempted by the VENDOR/CONTRACTOR only after getting specific concurrence from the EMPLOYER/PROJECT MANAGER and according to the approved procedures.

4.4.17.5. WELDING (a)

All welding involved in construction and fabrication of the plant and items covered under the PURCHASE ORDER/CONTRACT shall be carried out in accordance with specifications and applicable codes. 284

(b)

Welding procedures and welders' qualifications shall be approved by the EMPLOYER/PROJECT MANAGER. Where applicable, welders shall be tested as detailed in codes specified for pipe welding, vessel welding and structural welding and appropriate to the corresponding weld position using test pieces of appropriate parent metal to be used on the job. The EMPLOYER/ PROJECT MANAGER shall have the right to have any welder re-tested at any time during the PURCHASE ORDER/CONTRACT.

(c)

Recommendations of applicable codes shall be followed for non-destructive tests, wherever applicable.

(d)

Copies of all welding procedures, procedure qualification records, welders' performance qualification certificates, post-heating and stress relieving records, NDT records and other test results shall be made available upon request of the EMPLOYER/PROJECT MANAGER.

4.4.17.6. FABRICATION AND INSPECTION (a)

Fabrication and inspection procedures for vessels, heat exchangers, pipes, tubes and valves etc. shall be in accordance with procurement specifications, quality plan, applicable codes or any other approved equal.

4.4.17.7. TESTS AT MANUFACTURER'S WORKS (a)

GENERAL The tests at works shall include electrical, mechanical and hydraulic tests in accordance with the appropriate clauses of Statutory Regulation, relevant codes and standards and approved drawings and specifications and in addition any test called for by the EMPLOYER/PROJECT MANAGER to ensure that the plant being supplied fulfils the requirements of the specifications. The VENDOR/ CONTRACTOR shall carry out all the shop tests and inspections specified under individual items of the equipment in Data Sheets of the enquiry document, in addition to those normally required as per codes and standards. For items not covered by any code or specifically mentioned in the specifications, the tests are to be agreed with by the EMPLOYER/PROJECT MANAGER. If considered necessary by the EMPLOYER/PROJECT MANAGER, multi-part assemblies shall be fully erected and tested in the works prior to packing and despatch to the site.

(b)

TEST CERTIFICATES Test certificates including test records, performance curves and balancing certificates shall be supplied according to the Distribution Schedule. All the tests shall be carried out in accordance with the provisions of the PURCHASE ORDER/CONTRACT. All test certificates must be endorsed with sufficient information to identify the material or the equipment to which the certificates refer, and must carry at the top right hand corner the identification of the EMPLOYER/PROJECT MANAGER and the PURCHASE ORDER/CONTRACT.

(c)

CALIBRATION 285

All instruments used for critical measurement such as pressure gauges for leak tests, instruments for measuring performance parameters; instruments for precision dimension measurements shall have valid calibration certificates traceable to national standards. This means that the calibrating agency engaged by the VENDOR/CONTRACTOR shall use instruments which are in turn calibrated by Government approved agencies and such information shall be recorded in the calibration certificate issued by the calibrating agency by giving the certificate number, date and date of validity of the certificate given by the Government approved agency.

286

4.5

LIST OF APPROVED MAKES

4.5.1 FIRE PROTECTION SYSTEM This section provides details of the Approved Vendors / Approved makes for bought-out items, which form a part of this enquiry package. BIDDER shall clearly indicate the makes of all bought-out items and shall at no point in time during execution shall deviate from those indicated in the offer document. NOTE: - All materials and products shall conform to the relevant standards and shall be of approved make and design. A list of manufacturers/ vendors is given separately herein below for guidance. The Engineer shall give the approval of a manufacturer/ vendor/ only after review of the sample/ specimen. In case the same is not available in the market or in case of change in trade name, equivalent makes/ re-designated manufacturer then an equivalent approved make shall be used with the approval of Employer/ Engineer. The complete system and installation shall also be in conformity with applicable Codes & Standards and Tender specifications. - Only “First” class quality materials shall be used. - Employer reserves the right to choose any of the approved make / vendors as per this list. - In case of products not indicated in this list, bis marked products shall be preferred. - Specification of manufacturer‟s item shall be checked against tender item / specifications before selecting any product or brand name. In case of any discrepancy, tender item/ specifications shall prevail, and any such brand of item shall not be used which is not conforming to tender specifications even if it is listed in this list. - For use of material from a bis listed/ certified manufacturer, the contractor shall furnish a copy of the BIS certificate to Employer before procuring the material. - In case non-availability of any item/ material among approved manufacturers/ brands at a particular site/ region, alternate manufacturers/ brands conforming to BIS/ BS etc. shall be used subject to approval by Employer. - In case of non-availability of any manufacturer among approved manufacturers at a particular site/ region, alternate manufacturer‟s name shall be proposed along-with required credentials for Employer‟s approval. - In case of any item/ product neither covered in this list nor having A BIS specifications, the contractor shall submit the proposed item/ product along-with technical details/ specifications (as per bid), test certificates etc. And other credentials of the manufacturer for Employers approval. LIST OF APPROVED MAKES FOR PRODUCTS AND MATERIALS FOR FIRE PROTECTION WORKS ARE INDICATED IN THE TABLE BELOW. HOWEVER, ANY OTHER MAKE WHICH IS EQUIVALENT AND MEETING THE TENDER SPECIFICATIONS ARE ALSO ACCEPTABLEWITH PRIOR APPROVAL OF THE ENGINEER 287

SR. NO.

ITEMS

MANUFACTURER

1.

Pump

Grundfos/ KBL/ Mather & Platt / Armstrong/ Greaves Ltd.

2.

Motors

Refer Appendix-2 of specification for approved/preferred makes of electrical items.

Any other make subjected to prior approval of Employer / Project Manager.

4.5.3

INSTRUMENTATION & CONTROL SYSTEM This section provides details of the Approved Vendors / Approved makes for Electrical and I&C items, which form a part of this tender. For any other type of item/instrument; makes shall be subject to Employer's/Project Manager's Approval. Sr. No

The design, materials, construction, manufacture, inspection, testing and performance of split airconditioners shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility. In particular, the split air-conditioners shall conform to the latest editions of following standards: a) b)

5.1.3.1 CABINETS The split air-conditioners comprise of two cabinets viz. indoor unit (IDU) and condensing/outdoor unit (ODU). Indoor unit shall house air handling fan, cooling coil, insulated drain tray and filter. The unit shall be of heavy gauge steel, corrosion resistant, finished with synthetic enamel paint and acoustically insulated with resin bonded fiberglass or equivalent material. Suitable drain connection shall be provided for removal of condensate collected inside the drain tray under cooling coil. The front panel shall be decorative type with supply air grille of adjustable type and having adequate return air passage. The front panel shall be made of plastic or aluminum and shall be easily removable for cleaning of filter. The unit shall be suitable for wall mounting and can also be ceiling suspended. Condensing/outdoor unit shall house compressor and condenser and shall be of heavy gauge corrosion resistant carbon steel and shall be suitable for mounting in open space (e.g. on terrace or on outside wall).

292

5.1.3.2 COMPRESSOR The compressor shall be hermetic Scroll or Rotary and shall be mounted on vibration absorbers. Necessary crank case heaters shall be provided. 5.1.3.3 CONDENSER The air cooled condenser shall be with copper tubes and aluminium fins with low noise fan(s). Speed of axial fan(s) shall not exceed 960 RPM for fan with impeller diameter above 450 mm and 1440 RPM for fan with impeller diameter 450 mm and less. The impeller shall be statically and dynamically balanced. Condenser coil shall have anti-corrosion treatment. 5.1.3.4 AIR HANDLING FAN The fan shall be centrifugal type with forward curved impeller. The impeller shall be statically and dynamically balanced. 5.1.3.5 COOLING COIL AND FILTER The cooling coil shall be of direct expansion type with copper tubes and aluminium fins. This shall be minimum three (3) rows deep and with minimum three (3) fins per centimetre. The air before it enters the cooling coil shall be filtered by dry and cleanable type filter. 5.1.4

REFRIGERATION PIPING AND CONTROLS

5.1.4.1 The refrigeration piping shall be complete with externally equalised thermostatic expansion valve, liquid line strainer, dehydrator with replaceable drying agent and liquid line shut-off valve. 5.1.4.2 Refrigerant piping, fittings, piping joints shall conform to the requirements of ANSI B 31.5. 5.1.4.3 The piping shall be designed for an internal pressure representing the most severe condition of coincident pressure and temperature expected in normal operation. 5.1.4.4 Vacuum testing shall be done for medium vacuum of around 40 mm Hg absolute and held with vacuum pump in operation for at least 4 hours. Thereafter unit shall be sealed and vacuum held for at least 12 hours. Vacuum break shall be done using refrigerant and pressure raised to standing pressure in refrigerant cylinder. 5.1.4.5 ON-OFF thermostat with adjustable setting shall be provided for temperature control. A selector switch enabling the running of the air handling fan alone or fan with cooling shall be provided. Interlock shall be provided such that compressor can start only after starting the air handling fan. Provision shall also be made to interlock the compressor with the air cooled condenser fan motor. Safety devices such as high/low refrigerant pressurestat (HP/LP) and compressor oil pressurestat (OP), hermetic motor winding thermostat etc. shall be provided. HP and OP cut out shall be manual reset type while LP cut out shall be auto reset type.

293

5.1.4.6 Refrigerant and oil shall be supplied along with the unit. The refrigerant and oil charging shall be carried out at site. Exposed refrigerant piping shall have anti-corrosive coating. 5.1.5

ELECTRICAL

5.1.5.1 A sequential controller shall be provided if asked for in Datasheet A. This controller shall facilitate the automatic periodic switching of the units from working to standby mode in a predefined sequence so that all the units shall be in operation for a defined period of time. This system shall be required in (N+1) OR (N+2) type combination of working & standby units. 5.1.5.2 The unit shall be provided with single phase preventers for all motors. 5.1.5.3 Each SAC shall be provided with three pin Plug and cable. 5.1.5.4 The indoor and outdoor units shall be pre-wired at the factory and shall be complete with starters for all motors. 5.1.5.5 Wiring between indoor and outdoor units shall be carried out at site. 5.1.5.6 Cordless remote controller shall be provided. Remote controller shall have ON/OFF & temperature control option. 5.1.6

PERFORMANCE GUARANTEE

5.1.6.1 Performance guarantees for the Split Air conditioners (SAC) shall be as specified in data sheet- A. 5.1.7

DATA SHEET – A

SL. NO.

ITEM

1.0

GENERAL

1.1

DESIGNATION

SPLIT ACS FOR SERVE ROOM

1.2

NUMBERS REQUIRED: TABLE HAS Nos. GIVEN BELOW

TABLE HAS GIVEN BELOW

1.3

TAG NUMBERS: TABLE HAS GIVEN BELOW

811-SAC-01 & 02

1.4

REFRIGERANT USED

R-410a/ R407C

1.5

STAR RATING (BEE)

3/4/5

1.6

OPERATION

CONTINUOUS / INTERMITTENT hrs/DAY

2.0

DESIGN DATA

2.1

REQUIRED

UNIT

MINIMUM

ACTUAL TR

2.0 294

SL. NO.

ITEM

UNIT

CAPACITY REQUIRED 2.2

DESIGN OUTDOOR CONDITIONS

2.2.1

DRY BULB TEMPERATURE

0

42.0

2.2.2

WET BULB TEMPERATURE

0

26.8

2.3

DESIGN INDOOR CONDITIONS

2.3.1

DRY BULB TEMPERATURE

0

20.0

2.3.2

WET BULB TEMPERATURE

0

14.5

3.0

INDOOR UNIT

3.1

TYPE

HI-WALL / CASSETTE / FLOOR

3.2

REQUIRED DEHUMIDIFIED AIR FLOW CAPACITY OF EACH INDOOR UNIT

MINIMUM 330 CFM / TR

C C

C C

3.3

FILTRATION

3.3.1

ANTIDUST FILTERS (PRE-FILTERS)

YES / NO

3.3.2

DEODORIZATION FILTERS

YES / NO

3.3.3

ANTI-BACTERIA FILTERS

YES / NO

3.4

ULTRAVIOLET SCREEN

YES / NO

3.5

FAN TYPE

FORWARD CURVED, COUPLED

3.6

FAN SPEED

SINGLE / MULTISPEED

3.7

FAN MOTOR TYPE

STD / FLAMEPROOF

3.8

NOISE LEVEL @ 1.0 M FROM UNIT

3.9

NO. OF UNITS / OUTDOOR

ONE / TWO

3.10

RETURN GRILLE

FRONT / TOP

3.11

COOLING COIL

INNER GROOVED COPPER

3.12

FINS

ALUMINUM

3.13

ANTI-CORROSIVE COATING ON COIL

YES / NO

4.0

OUTDOOR UNIT

4.1

COMPRESSOR

HERMETIC SCROLL / ROTARY / RECIPROCATING

4.2

VIBRATION ISOLATORS

NEOPRENE RUBBER PADS

4.3

NOISE LEVEL @ 1.0 M FROM UNIT

4.4

ANTI-CORROSIVE BODY

4.5

ANTI-CORROSIVE COATING ON COIL

COATING

dB(A)

dB(A) ON

45 (MAXIMUM)

65 YES / NO YES / NO 295

SL. NO.

ITEM

4.6

FAN TYPE

AXIAL, PROPELLER

4.7

FAN SPEED

SINGLE / MULTISPEED

5.0

ELECTRICAL

5.1

OUTDOOR MOTOR

AS PER MFR‟s STD

5.2

POWER SUPPLY

230V, 1 PHASE, 50 Hz

5.3

POWER SUPPLY LOCATION

NEAR INDOOR UNIT / AT BOTH LOCATIONS

5.4

MINIMUM PLUG & SOCKET

6.0

INTERCONNECTED PIPING

6.1

MAXIMUM PERMISSIBLE DISTANCE BETWEEN IDU AND ODU

6.1.1 6.1.2

UNIT

CABLE

LENGTH

WITH m

3

VERTICAL

m

15

m

25

m

UP TO 7

6.3.1

TOTAL INSULATED REFRIGERANT PIPING BETWEEN IDU AND ODU ACCESSORIES IN REFRIGERANT PIPING ECONOMIZER

TOTAL POWER INPUT AT DESIGN kW CONDITION DEHUMIDIFIED AIR FLOW OF m3/hr INDOOR UNIT NOISE LEVEL

9.4.1

AT INDOOR UNIT @ 1.0 M

dB(A)

45

9.4.2

AT OUTDOOR UNIT @ 1.0 M

dB(A)

75

10.0

COST LOADING AND PENALTY

10.1

FOR DIFFERENTIAL TOTAL POWER Rs/kW INPUT AT DESIGN CONDITIONS

11.0

TESTS AND INSPECTION

11.1

AS PER STANDARD

5.1.8

SPLIT AC DETAILS:

9.2 9.3

Sr. No.

Building Name

A

ADMIN BUILDING

A.1

SECOND FLOOR

1.1

SERVER ROOM

Selected

(sqft.)

(TR)

TR

Qty Nos

273

2.50

1.5 1

1 1

1.50

Configuration of IDU

2.00

2.50

1 1 1

1.00

3.00

3.50

2.50

Total TR

Model/ Type

1.00

EXECUTIVE HOSTEL

B.1

GROUND FLOOR

1.1

GUEST ROOM-2

153

1.2

GUEST ROOM-1

153

1.3

LOUNGE

221

SUB TOTAL B.2

660 Min.

Area

TOTAL B

2.4 Max.

1.00 1.00 1.50 3.50

1 1 1.5

1.00 1.50

Split AC Window AC

FIRST FLOOR 297

2.1

GUEST ROOM-3

153

2.2

GUEST ROOM-4

153

2.3

GUEST ROOM-5

153

2.4

GUEST ROOM-6

153

C

1.00 1.00 1.00 1.00

1 1 1 1

1 1 1 1

1.00 1.00 1.00 1.00

SUB TOTAL

4.00

4.00

4.00

TOTAL

7.50

7.00

7.50

1 1 1 1 2 1

1.00

7.00

13.50

Split AC

DINING BLOCK

C.1

GROUND FLOOR

1.1

DISPENSARY LOBBY

119

1.2

EXMINATION RM

105

1.3

WARD

102

1.4

INJECTION RM

102

1.5

BANK COUNTER

320

1.6

KITCHEN

307

SUB TOTAL

1.00 1.50 1.50 1.00 3.00 5.50

1 1.5 1.5 1 1.5 5.5

13.50

1.50 1.50

Window AC

1.00 3.00 5.50

Split AC TFA

C.2

FIRST FLOOR

2.1 2.2

KIOSK EXECUTIVE DINING

142 1369

1.50 6.50

1.5 1.5 2

1 3 1

1.50 4.50 2.00

Split AC

KITCHEN

306.6 6

5.50

5.5

1

5.50

TFA

6.00 13.0 0

13.50

2

3.00

2.00

3.00

2

3.00

2.3

D 1.1

SUB TOTAL

13.50

TOTAL

27.00

TRAINING SERVER ROOM

286

TOTAL

E

27.00

3.00

1.5

3.00

UTILITY BLOCK

E.1

GROUND FLOOR

1.1

UPS ROOM GRAND TOTAL

271

3 37.50

1.5

Split AC

37.50

298

5.2

AIR-COOLED VARIABLE REFRIGERANT FLOW SYSTEM

5.2.1

SCOPE

The scope of this section comprises the supply, erection testing and commissioning of inverter based Variable Refrigerant Volume System with Scroll Compressor conforming to these specifications and in accordance with the requirements of drawing and Schedule of Quantities. 5.2.2

TYPE

Units shall be air cooled, variable refrigerant volume air conditioner of R410A gas based consisting of outdoor unit and multiple indoor units. Each indoor units having capability to cool or heat independently for the requirement of the rooms. It shall be possible to connect several indoor units on one refrigerant circuit. The indoor units on any circuit can be of different type and also controlled individually. Following type of indoor units shall be connected to the system: a. Floor Mounted Packaged units b. Ductable type c. Wall hung Both indoor units and outdoor unit shall be factory assembled, tested and filled with first charge of refrigerant before delivering at site. 5.2.3

OUTDOOR UNIT

The outdoor unit shall be factory assembled, weather proof casing, constructed from heavy gauge mild steel panels and coated with baked enamel finish. The unit should be completely factory wired tested with all necessary controls and switch gears: The outdoor unit shall be modular in design and should be allowed for side by side installation. The outdoor unit shall be provided with welded steel support with two coats of paint for erection purpose. a. All outdoor units above 8 HP shall have minimum two scroll compressors and be able to operate even in case one of compressor is out of order. b. In case of outdoor units above 14HP, the outdoor unit shall have at least 2 inverter compressors and inverter motor of brushless DC Type so that the operation is not disrupted with failure of any compressor. c. It should also be provided with duty cycling for switching starting sequence of multiple outdoor units. d. The noise level shall not be more than 68 dB (A) at anechoic chamber conversion value, measured horizontally 1m away and 1.5m above ground level. e. The outdoor unit shall be modular in design and should be allowed for side by side Installation. f. The unit shall be provided with its own microprocessor control panel. The outdoor unit should be fitted with low noise, aero spiral design fan with large airflow and should be 299

designed to operate compressor-linking technology. The unit should also be capable to deliver 78 Pa external static pressure to meet long exhaust duct connection requirement. The condensing unit shall be designed to operate safely when connected to multiple fan coil units, which have a combined operating nominal capacity up to 160 % of indoor unitsfor outdoor units up to 40 HP. 5.2.4

COMPRESSOR

The compressor shall be highly efficient scroll type and capable of inverter control. It shall change the speed in accordance to the variation in cooling or heating load requirement: The inverter shall be IGBT type for efficient and quiet operation. All outdoor units shall have at least 10 to 30 steps of capacity control to meet load fluctuation and indoor unit individual control. All parts of compressor shall be sufficiently lubricated stock. Forced lubrication may also be employed. Oil heater shall be provided in the compressor casing. C.O.P for the units shall not be less than 4.5. 5.2.5

HEAT EXCHANGER

The heat exchanger shall be constructed with copper tubes mechanically bonded to aluminum fins to form a cross fin coal. The aluminum fins shall be covered by anti-corrosion resin film. The unit shall be provided with necessary number of direct driven low noise level propeller type fans arranged for vertical discharge. Each fan shall have a safety guard. 5.2.6

REFRIGERANT CIRCUIT

The refrigerant circuit shall include liquid & gas shut-off valves and a solenoid valves at condenser end. All necessary safety devices shall be provided to ensure the safely operation of the system. 5.2.7

SAFETY DEVICES

All necessary safety devices shall be provided to ensure safe operation of the system. Following safety devices shall be part of outdoor unit; high pressure switch, fuse, crankcase heater, fusible plug, over load relay, protection for inverter, and short recycling guard timer. 5.2.8

OIL RECOVERY SYSTEM

Unit shall be equipped with an oil recovery system to ensure stable operation with long refrigeration piping lengths. 5.2.9

INDOOR UNIT

300

This section deals with supply, installation, testing, commissioning of various type of indoor units confirming to general specification and suitable for the duty selected. The type, capacity and size of indoor units shall be as specified in detailed Bill of Quantities. 5.2.10 GENERAL Indoor units shall be wall mounted type or ceiling mounted ductable type as specified in BOQ. These units shall have electronic control valve to control refrigerant flow rate respond to lead variations of the room. a. The address of the indoor unit shall be set automatically in case of individual and group control b. There shall be localized control only. The fan shall be dual suction, aerodynamically designed turbo, multi blade type, statically & dynamically balanced to ensure low noise and vibration free operation of the system. The fan shall be direct driven type, mounted directly on motor shaft having supported from housing. The cooling coil shall be made out of seamless copper tubes and have continuous aluminum fins. The fins shall be spaced by collars forming an integral part. The tubes shall be staggered in the direction of airflow. The tubes shall be hydraulically/ mechanically expanded for minimum thermal contact resistance with fins. Each coil shall be factory tested at 21kg/sqm air pressure under water. Unit shall have cleanable type filter fixed to an integrally molded plastic frame. The filter shall be slide away type and neatly inserted. Each indoor unit shall have computerized PID control for maintaining design room temperature. Each unit shall be provided with microprocessor thermostat for cooling and heating. The outdoor unit shall be pre-charged with first charge of R 410A refrigerant. Additional charge shall be added as per refrigerant piping at site. All the units shall be suitable for operation with 380 415 V 50 Hz + 3%, 3 Phase supply for outdoor units & 220 – 240 V, 50 Hz + 3%, 1 Phase supply for in-door units. 5.2.10.1

The units shall be integrated with Fire Alarm system and in case of fire all units shall be switched off.

The outdoor units must be suitable for up to 150m (straight length) refrigerant piping between outdoor unit & the farthest indoor units, total piping of 500m for all the indoor units. Allowable level difference between outdoor unit & indoor units shall be 50m in case of outdoor unit on top & 40 m in case of outdoor unit at bottom. Allowable level difference between various indoor units connected to one out door unit shall be up to15m. 301

5.2.10.4

The outdoor unit shall employ system of equal run time for all the compressors, inverter or on/ off type, within each outdoor unit – Single Module or Multi Module.

These units shall be ceiling suspended with suitable supports to take care of operating weight of the unit, without causing any excessive vibration & noise. The cold air supplied by these units will be supplied to the area to be air conditioned, through duct system specified in the tender.

5.2.11.3

Each indoor unit must have electronic expansion valve operated by microprocessor thermostat based temperature control to deliver cooling/ heating as per the heat load of the room.

302

5.2.11.4

Unit must be insulated with sound absorbing thermal insulation material, Glass Fiber. The noise level of unit at the highest operating level shall not exceed 49 dB(A), at a vertical distance of 1.5 m below the units with duct connected to the unit.

5.2.11.5

Unit must have Thermal Fuse for fan motor protection, in case of motor heating. The unit will be connected in series to a suitable outdoor unit & it must be possible to operate the unit independently, through corded/ cordless remote specified in the bill of quantities. The unit will be further connected to Intelligent Building Management System (To be supplied by other vendors) & it shall be possible to operate the unit through this IBMS system.

This specification covers the technical requirements and essential particulars for the supply, application and finishing of the complete thermal insulation for cold equipment, piping systems, airconditioning ducts etc. for temperatures between ambient and (-) 80oC and also for dual temperatures (both hot and cold) service with hot temperature above ambient and up to 230 oC. Unless specified otherwise in data sheet A, the scope of supply of the CONTRACTOR shall include, but not be limited to, the following items: a. Insulation materials of all types as specified and required b. Insulation adhesives, vapour barriers and finishing materials of all types as specified and required c. Auxiliary materials such as binding and lacing wires, wire netting, bands, screws, pop rivets etc., as specified and required d. Angles, clamps, lugs etc. for supporting insulation e. Weather hoods f. Any other material as may be required for making the insulation complete 5.3.2

CODES AND STANDARDS

The supply and application of thermal insulation and finishing covered under this specification shall comply with all currently applicable statutes, regulations and safety codes in the locality where it is to be applied. The materials and application shall also conform to the latest editions of the codes and standards listed. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility. 5.3.2.1 The following are some of the codes and standards relevant to this specification : IS 277

Galvanised Steel Sheets (Plain and Corrugated)

IS 737

Wrought Aluminium and Aluminium Alloy Sheet and Strip for General Engineering Purposes

IS 3144

Mineral Wool Thermal Insulation Materials - Method of Test

IS 3677

Unbonded Rock and Slag Wool for Thermal Insulation

IS 4671

Expanded Polystyrene for Thermal Insulation Purposes

IS 8183

Bonded Mineral Wool

IS 9842

Preformed Fibrous Pipe Insulation

IS 14164

Industrial Application and Finishing of Thermal Insulation Materials at Temperatures above (-) 800C and up to (+) 7500C 309

5.3.3

BS 3927

Rigid Phenolic Foam (PF) for Thermal Insulation in the Form of Slabs and Profiled Sections

5.3.3.1 GENERAL All materials shall be new and fresh, incombustible, fire retardant, rot-proof, nonhygroscopic, vermin proof, fungus proof, non-injurious to health, chemically inert, non-corrosive to steel and aluminium (even if soaked in water for extended periods) and shall be guaranteed to withstand continuously and without deterioration the minimum and maximum temperatures to which these shall be subjected to under the specified applications. 5.3.3.2 The insulation materials and any component of the finished insulation job shall not react chemically, singly or in combination, with water or moisture to form substances that are more actively corrosive to applied surface than water or moisture alone. 5.3.3.3 In order to protect the workers from the hazards of insulation materials, suitable protective gadgets shall be provided. Required safety precautions shall be taken during handling and application of insulation. 5.3.3.4 The insulation material shall be kept dry at all times during transport, storage and installation. Decking and covering tarpaulins alone are not adequate for any length of time and shall not be allowed except in extreme emergencies and only for short period. Stacking of insulation materials directly on ground shall not be done. No wet insulation shall be installed. If wet insulation is present, it shall be removed and replaced with new dry insulation. The insulation may be protected with plastic film but shall be vented to prevent sweating. 5.3.4

INSULATION MATERIALS

The insulation material shall be one or more of the following types as specified in data sheet A. SL. INSULATION MATERIAL NO.

STANDAR DENSIT TEMP. D Y, Kg/M3 RANGE, 0C

MATERIA L CODE

1.

Fire-retardant quality expanded IS 4671 polystyrene

20

(-)80 to 80

EP

2.

Rigid polyurethane Polyisocyanurate foam

32

(-)80 to 110

PUR/ PIR

/ BS 5608

310

3.

Phenolic foam

4.

32

(-)80 to 130

PF

Lightly resin-bonded glass wool IS 8183 mattresses

32

(-)40 to 230

LRG

5.

Resin-bonded glass wool pipe IS 9842 sections

85

(-)40 to 230

PSG

6.

Unbonded rock and slag wool

150

(-) 80 to 230

U150

5.3.5

BS 3927

IS 3677

INSULATION ADHESIVES

The insulation adhesive shall be one or more of the following types as specified in data sheet A. Material Description

Material Code

1.

Hot bitumen of grade 85/25 or 85/40 conforming to IS 702 shall BIT be uniformly applied at 1.5 Kg/M2 on the surface to be insulated. A similar layer shall also be applied on the inside surface of the insulation. This material shall not be used for stainless steel surfaces.

2.

CPRX compound shall be uniformly applied at 1.5 Kg/M2 on the CPRX surface to be insulated. A similar layer shall also be applied on the inside surface of the insulation. This material shall not be used for stainless steel surfaces.

3.

MAS 83 with 0.5 mm wet film thickness shall be uniformly MAS 83 applied at 0.5 lit/M2 by trowelling. MAS 83 shall not be used with polystyrene as insulation material. MAS 83 can be used only between (-) 46 and (+) 149oC.

5.3.6

VAPOUR BARRIERS

The vapour barrier shall be one or more of the following types as specified in data sheet A. Material Description 1.

be uniformly applied at 2.5 Kg/M2 on the outer surface of insulation and allowed to dry. Reinforced Plastic (RP) tissue paper shall be applied on the dried bitumen. This material shall not be used for stainless steel surfaces. 2.

0.1 mm thick factory-laminated aluminium foil with craft paper ALF shall be provided. All joints shall be provided with 50 mm overlap and all joints shall be sealed with aluminium tape. For temperature between (-) 43 and (+) 149oC MAS 35 may also be used as sealant.

3.

MAS 130 with 1.02 mm wet film thickness primer coat at 1.0 MAS 130 lit/M2 and 2.25 mm wet film thickness finish coat at 2.5 lit/M2 shall be uniformly applied over the insulation by spatula or trowelling. MAS 130 shall not be used with polystyrene as insulation material. MAS 130 can be used only between (-) 40 and (+) 60oC.

5.3.7

FINISHING MATERIALS

The finishing material shall be one or more of the following types as specified in data sheet A.

Material Description

Material Code

Portland cement and inorganic fibre with water proofing compound at an FC application density of 1050 to 1100 Kg/M3. Aluminium sheet as per IS 737, designation 31000, condition H3. (a)

Insulation outside diameter above 450 mm - sheet thickness 18 SWG

(b)

Insulation outside diameter 150 to 450 mm - sheet thickness 20 SWG

(c)

Insulation outside diameter below 150 mm - sheet thickness

(d)

Air-conditioning ducts - sheet thickness

(e)

Equipment - sheet thickness

AL1

AL1

312

Galvanized Steel (GS) sheet as per IS 277, designation GP (a)

Insulation outside diameter above 450 mm - sheet thickness 20 SWG

(b)

Insulation outside diameter 150 to 450 mm - sheet thickness 22 SWG

(c)

Insulation outside diameter below 150 mm - sheet thickness 24 SWG

(d)

Air-conditioning ducts - sheet thickness 26 SWG

(e)

Equipment- sheet thickness 20 SWG

MAS 134 with 1.0 mm wet film thickness at 1.0 lit/M2 shall be uniformly applied when using over porous insulation materials. Wet film thickness shall be 0.5 mm at 0.5 lit/M2 for impervious insulation surfaces including polystyrene. MAS 134 can be used only between (-)18 and (+) 82oC.

5.3.9.1 GENERAL The application of insulation shall be made in a professional manner. The insulation shall be applied to all surfaces when these are at ambient temperature. Ample provision shall be made for the maximum possible thermal movement and the insulation shall be applied in a manner which shall avoid breaking or telescoping due to alternate periods of contraction and expansion. A single layer of insulation shall not be more than 75 mm thick. 5.3.9.2 Insulation shall be applied after all leak tests on equipment and piping are over and the section of the plant has been specifically released by the EMPLOYER for such work. If insulation has to be applied before the leak test, all welded and flanged joints shall be left exposed and insulated after satisfactory completion of the leak test. 5.3.9.3 All surfaces to be insulated shall be clean and dry before the insulation is applied. The surfaces shall be cleaned of all foreign material such as scale, dirt, rust and paint, by the use of steel wire brushes and steel scrapers, where necessary. Where a surface is not free of paint the CONTRACTOR shall notify the EMPLOYER of the condition for remedial action. The insulation shall be applied after remedial action, suggested by the EMPLOYER, has been taken by the CONTRACTOR. One coat of primer paint shall be applied and allowed to dry before application of insulation. 5.3.9.4 After cleaning and application of one coat of primer paint on the surface to be insulated, the insulation adhesive shall be applied for fluid operating temperatures between 200C and (-) 200C. Insulation material of required thickness shall be stuck to the surface with joints staggered. The adjoining sections shall be tightly pressed together. All the joints shall be sealed with adhesive material. Voids, if any, shall be packed with suitably cut pieces of insulation material. Vapor barrier and insulation finish shall be applied as per Para‟s 3.4 and 3.5 or 4.5 respectively. 5.3.9.5 For fluid operating temperatures below (-) 200C, the insulation shall be applied directly over the surface to be insulated without applying the insulation adhesive. Vapor barrier shall be applied over the insulation material. Vapor barrier and insulation finish shall be applied as per Para‟s 3.4 and 3.5 or 4.5 respectively. 5.3.9.6 Where multilayer insulation is provided, insulation adhesive shall be used between two layers, based on temperature criterion given in Para 4.1.4.

314

5.3.9.7 If aluminium or GS sheet is specified as finishing material, all joints shall be sealed with bitumastic paint and made effectively weather and water-proof. For temperatures between (-) 40 and (+) 120oC, MAS 94 may also be used as sealant. MAS 94 shall, however, not be used with polystyrene as insulation material. All flat surfaces shall be adequately sloped to prevent pools of water collecting. The sheet shall be protected internally with 2 coats of bitumastic paint. 5.3.9.8 All actions shall be taken to complete the application of finishing on exposed surfaces covered with insulation before closing the day's work. If this is not practicable, adequate precautions shall be taken to protect the insulation from weather, for example by wrapping it with polythene sheet, roofing felt or other approved material. 5.3.10 PIPES, PIPE FITTINGS, VALVES AND SPECIALITIES 5.3.10.1 All vertical pipes shall be provided with suitable insulation supports to prevent the insulation from collapsing due to its own weight. Any welding required, shall be carried out by the CONTRCATOR with the prior permission of the EMPLOYER and only under his direct supervision. Where welding is not permitted, suitable clamped supports shall be used. The insulation shall be applied starting from bottom up. Mattress type insulation materials shall be clamped from top.

5.3.10.2 All pipe fittings, valves and specialties shall be covered with the same type and thickness of insulation as specified for the adjoining pipe. On pipe fittings, insulation outside diameter shall be same as the outside diameter of adjacent pipe insulation. Unless specified otherwise, valves and specialties of sizes 100 mm NB and larger shall be provided with removable box type insulation. Box shall be fabricated from sheet material specified for adjoining pipes. Pipe insulation on adjoining flanges shall be stopped at one bolt length plus 25 mm before flange to permit removal of the bolts and nuts. The insulation shall be applied after the finish has been applied over insulation on the adjacent piping. Flanged joints shall also be insulated with removable type of boxes. Arrangement shall be similar to that for valves. 5.3.10.3 The sheets shall be installed with the longitudinal lap joints at 450 below the horizontal for horizontal pipes and the joints sealed with bitumastic paint. 5.3.10.4 On vertical pipes the sheets shall be applied working from bottom up. Each section of sheets shall have a minimum overlap of 50 mm longitudinally and circumferentially. Each circumferential joint shall be made weather-proof by securing with a band of sheet material and sealing with bitumastic paint. Longitudinal lap joints shall be fixed with screws or pop rivets at approximately 150 mm centers. 5.3.10.5

Valves shall be insulated up to and including their bonnet flange.

5.3.10.6

Insulation of pipe hanger clamps shall be as per Standard. 315

5.3.10.7 Weather hoods shall be provided for insulated piping passing through roof and external walls as per standard.

5.3.11 EQUIPMENT 5.3.11.1 Where the insulation material is in the mattress form, cleats in the form of wire nails or nuts or angles and flats for supporting the insulation material, shall be welded to the equipment by others. If wire nails are to be used as insulation cleats, these shall be bent and secured with the metal fabric of the mattress, after the insulation has been applied. Where insulation cleats are in the form of M6 and M10 nuts, the CONTRACTOR shall supply and install bolts of suitable length for fixing the insulation. The insulation applied to equipment shall be reinforced with wire netting. One course of wire netting shall be applied to the surface of the equipment and each layer of insulation shall be backed up with wire netting. All irregularities of the surface shall be filled and leveled over with insulating cement. All mattress joints shall be butted tightly and the mattresses shall be secured with 20 mm wide 24 SWG GS bands at 450 mm centers. After banding, all mattress edges shall be laced tightly. 5.3.11.2 All equipment, unless specified otherwise, shall have a smooth aluminum or GS sheet finish as specified in data sheet A, applied in a manner similar to that specified for piping. For fixing of aluminum or GS sheets, wooden spacer rings at 1000 mm centers shall be fixed to the equipment by the CONTRACTOR. All vertical and horizontal sheets shall be overlapped a minimum of 75 mm. The lapped joints of adjoining sections of sheets shall be secured with screws or pop rivets. On all equipment above 2500 mm diameter and flat surfaces, the sheet shall be further secured by circumferential bands at approximately 1000 mm centers. Each sheet joint shall be sealed with bitumastic paint. The roof sections shall overlap the side walls to prevent water seepage between insulation and the equipment wall. Side wall sheets shall be securely banded at intersections of the side wall and roof sections. 5.3.11.3 All equipment manholes, hatches, bolted or screwed cover plates, flanged ends etc. shall have removable box type insulation, with same thickness of insulation as for adjacent surfaces. Insulation adjoining such equipment openings shall be tapered towards these openings to permit removal of bolts, screws, heads, covers or plates with no damage to adjacent surface insulation or cover 5.3.11.4 Nozzles and other connections on tanks and other equipment shall be insulated in the same manner as the pipes. 5.3.11.5 Pump casing shall be completely insulated with removable type of boxes fabricated from the specified sheet material. Proper care shall be taken to maintain continuity of vapour barrier between static and removable portion of insulation. 5.3.11.6 Name plates on equipment shall not be insulated. Proper care shall be taken to eliminate seepage of moisture from such un-insulated portions into the insulating material. 5.3.12 CONTRACTION JOINTS IN INSULATION 316

Depending on the type of insulation material used and the operating temperature, contraction joints shall be provided for equipment or pipes to prevent rupturing or buckling when the cold surface contracts CEMENT SAND PLASTER FINISH Where cement sand plaster finish is specified following procedure shall be followed. 5.3.13 Indoor Application After the application of hot bitumen or CPRX compound vapor barrier, the surface shall be wrapped with GS wire netting, butting all the joints and lacing down with lacing wire. The ends of all wire loops shall be firmly twisted together with pliers, bent over and carefully pressed into the surface of insulation. A total of 15 mm thick finishing cement sand(1:4) plaster shall be applied in two layers after a GS wire netting is stretched over the entire surface of insulation material and securely fastened down. The plaster shall be hand trowelled over the wire netting to a smooth finish. The application of finishing plaster shall be terminated, at the end of day‟s work, at a contraction joint. 5.3.14 Outdoor Application After the application of the plaster as per procedure for indoor application, an additional 6 mm thick water-proofing compound Shalikote 30 or equivalent shall be applied in two layers. Outdoors, the finishing plaster shall be applied immediately after application of insulation. If this is not practicable, the CONTRACTOR shall take adequate precautions to protect the insulation from weather, e.g. by wrapping it with polythene sheet, roofing felt or other approved material. The cement sand plaster finish shall have the following properties: a. A light shower of rain, falling immediately after application shall not wash off the plaster. b. At any time, one week or more after application, it shall not shatter if struck a sharp blow with a 0.7 Kg hammer. Such a blow may damage the finishing locally but shall not cause large pieces to break away. c.

When set, it shall withstand prolonged exposure to the weather without additional protection.

5.3.15 DUAL TEMPERATURE INSULATION For dual temperature application, resin-bonded glass wool or unbounded rock or slag wool thermal insulation shall be provided, depending on the lower temperature limit given in Para 3.2. Insulation thicknesses shall be as indicated in Insulation Schedule (Equipment) and Insulation Schedule (Piping). The insulation application procedure shall be same as that for cold surfaces. 5.3.16 MEASUREMENT Measurement of insulation over equipment and piping shall be as per IS 14164. 317

Measurement for air-conditioning ducts shall be taken over finished insulation surface and 5% additional area shall be considered to account for reinforcement and flanged angle joints. 5.3.17 MISCELLANEOUS Approval of the EMPLOYER shall be obtained of samples of all materials and necessary test certificates of approved national laboratories, before dispatching these to site. Insulation shall not be applied until specific release is given by the EMPLOYER. 5.3.18

DATA SHEET - A 40 O C

1. AMBIENT TEMPERATURE :

13.

2.

14.

3.

15.

4.

16.

5.

17.

6. INSULATION MATERIALS

18.

6.1 EP/PUR/PIR/PF/LRG/U150

19.

6.2 PIPING EP/PUR/PIR/PF/LRG/

EQUIPMENT:

SYSTEMS

20.

:

PSG/U150

21.

6.3 AIR-CONDITIONING EP/PUR/

DUCT

22.

:

PIR/PF/LRG/U150

23.

6.4

24.

6.5

25.

7. INSULATION BIT/CPRX/

ADHESIVES

26.

:

MAS 83

27.

8. VAPOUR BARRIERS : VB1/ALF/MAS 130

28.

9. FINISHING MATERIALS 9.1 EQUIPMENT : 134

FC/AL1/GS1/MAS 30. TEST CERTIFICATES FOR ALL

9.2 PIPING SYSTEMS:FC/AL1/GS1/MAS 134 9.3 AIR-CONDITIONING FC/AL1/

DUCT

:

MATERIALS YES/NO

GS1/MAS 134

31.

9.4

32.

9.5

33.

REQUIRED

:

318

10. INSULATING CEMENT MATERIAL:

34.

SAME AS THE BASIC INSULATION

35.

MATERIAL

36.

319

5.4 5.4.1

PANEL TYPE AIR FILTERS SCOPE

This specification covers the design, materials, construction features, manufacture, shop inspection and testing at manufacturer's works, delivery at site, installation, testing, commissioning and carrying out performance test at site of Panel Type Air Filters. 5.4.2

CODES AND STANDARDS

The design, materials, manufacture, inspection, testing and performance of filters shall comply with all currently applicable statutes, regulations, codes and standards in the locality where the filters are to be installed. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility. In particular, the filters shall conform to the latest edition of following standards:

5.4.3

ASHRAE 52.1

Gravimetric and Dust - Spot Procedures for Testing AirCleaning Devices Used in General Ventilation for Removing Particulate Matter

IS 7613

Methods of Testing Panel Type Air Filters for Air-Conditioning and Ventilation Purposes

ISO 14644-1 AND 2

Cleanrooms and Environments

Associated

Controlled

GENERAL REQUIREMENTS

5.4.3.1 PRE-FILTER Pre-filter shall contain washable synthetic fibre or High Density Polyethylene (HDPE) media having 18G Galvanised Steel Sheet (GSS) frame. The filter media shall be supported with HDPE mesh on one side and aluminium on the other side. Filter frame shall be provided with suitable handles. The gravimetric efficiency of the pre-filter as per IS 7613 with test dust G3 (fused aluminium oxide dust) shall be 90% down to particle size of 20 microns or as specified in data sheet A. 5.4.3.2 FINE FILTER Fine filter shall contain HDPE filter media having 18G GSS frame. The filter media shall be supported with HDPE mesh on either side. Filter frame shall be provided with suitable handles. The gravimetric efficiency of the fine filter as per IS 7613 with test dust G2 (fused aluminium oxide dust) shall be 99% down to particle size of 5 microns or as specified in data sheet A. 5.4.3.3 HIGH EFFICIENCY PARTICULATE AIR (HEPA) FILTER 320

HEPA filter shall contain sub-micron glass fibre paper with or without aluminium separators having 18G aluminium frame. Filter media shall be designed for velocities not exceeding 1.25 metres per second. Filter frame shall be provided with suitable handles. HEPA filter shall have cold Di-OctylPhthalate (DOP) test efficiency of 99.97% down to particle size of 0.3 microns or as specified in data sheet A.

The design, materials, construction, manufacture, inspection, testing and performance of axial fans shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The equipment shall also conform to the latest applicable Indian or equivalent standards. Other international standards are also acceptable, if these are established to be equal or superior to the listed standards. Nothing in this specification shall be construed to relieve the VENDOR / CONTRACTOR of this responsibility. 5.5.3

CONSTRUCTION FEATURES

5.5.3.1 CASING Casing shall be provided with suitable supports. Access door shall be provided in the casing for easy access to motor and impeller. Suitable arrangement for mounting of motors shall be provided. 5.5.3.2 IMPELLER The impeller shall have blades of an airfoil design. Blades shall be mounted on streamlined hub. Impeller with fabricated blades are acceptable up to 450 mm impeller diameter. The impeller shall be statically and dynamically balanced. Adjustable pitch blades shall be provided if specified in data sheet A. 5.5.3.3 GENERAL Guide vanes shall be provided on the discharge side for vane axial fans. Belt driven fans shall be provided with V- belts, V-belt pulleys and belt guards. Pulleys shall have minimum two(2) grooves to prevent start-up failure and premature belt failure. Pulleys shall be statically and dynamically balanced. Belts shall have a minimum service factor of 1.5. Common base frame for belt driven fans shall be with adjustable rails for motors. Bolts, nuts and washers used shall be of non-corrosive material and of superior quality. Bearings shall have minimum life of 50,000 hours. 5.5.3.4 DRIVE MOTOR 324

Drive motor shall be rated at least 15 % higher than the power requirement at duty point or 10 % higher than the maximum power requirement at selected speed, whichever is higher. Starting torque requirements of fan shall also be considered while selecting the motor. 5.5.3.5 NOISE AND VIBRATION Noise level produced by any rotating equipment individually or collectively shall not exceed 85 dB(A) measured at a distance of 1.5 metres from the source in any direction. The overall vibration level shall be as per zones A and B of ISO 10816-1. Balance quality requirement shall be G 6.3 conforming to ISO 1940/1. 5.5.3.6 PERFORMANCE GUARANTEES Performance parameters to be guaranteed by the VENDOR/ CONTRACTOR and tolerances permitted shall be as indicated in data sheet A. BIDDER shall confirm acceptance of these by indicating values in data sheet B. Fan or any portion thereof is liable for rejection, if it fails to give any of the guaranteed performance parameters. 5.5.3.7 DATA SHEET – A GENERAL 1

SCOPE This specification covers the general design, materials, construction features, manufacture, shop inspection and testing at manufacturer's works, delivery at site, handling at site, installation, testing, commissioning and carrying out performance test at site of Air Handling Units (AHUs).

5.6.2

CODES AND STANDARDS The design, materials, manufacture, inspection, testing and performance of AHUs shall comply with all currently applicable statutes, regulations, codes and standards in the locality where the equipment is to be installed. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility. In particular, the AHUs shall conform to the latest edition of following standards:

5.6.3

IS 7613

Method of Testing Panel Type Air Filters for Air-Conditioning and Ventilation Purposes

ASHRAE 33

Method of Testing - Forced Circulation Air Cooling and Air Heating Coils

ASHRAE 52.1

Gravimetric and Dust-Spot Procedures for Testing AirCleaning Devices Used in General Ventilation for Removing Particulate Matter

Casing shall be of single skin or double skin construction as specified in sheet A.

data

5.6.3.3 Single Skin Construction AHU shall be of sectionalised construction fabricated out of 16G Galvanised Steel Sheet (GSS) or Cold Rolled Cold Annealed (CRCA) sheet. 5.6.3.4 Double Skin Construction Double skin wall panels shall be 25 mm thick made of GSS, pressure injected with polyurethane foam insulation of density 48 Kg/M3 and K factor not exceeding 0.02W/MoC. Double skin wall panels shall be fixed to 2.5 mm thick aluminium alloy twin box section structural framework with stainless steel screws. Outer sheet of the panels shall be made of 0.8 mm thick GSS pre-plasticised or powder coated. Inner sheet shall be 0.8 mm thick plain GSS. The entire frame work shall be mounted on a 100 mm (minimum) aluminium alloy channel base. The panels shall be sealed to the frame work by heavy duty "O" ring neoprene gaskets held captive in the framed extrusion. All panels shall be detachable or hinged. Hinges shall be made of die cast aluminium with stainless steel pivots. Handles shall be made of hard nylon and be operational from both inside and outside of the unit. Units supplied with various sections shall be suitable for on-site assembly match drilled, with bolts, nuts and continuous neoprene rubber gaskets. All fixing and gaskets shall be concealed. Floor and roof panels shall be double skin type and shall be of same construction as the wall panels. AHUs shall have hinged quick-opening insulated access door on fan and filter sections. Access doors shall be double skin type and shall be of same construction as the wall panels. Four (4) lifting lugs shall be bolted to each base section for lifting or placing the AHU in place. All connecting fasteners and related hardware and its accessories shall be in stainless steel. 3.2.3 Sloping condensate drain pan shall be fabricated from 18G GSS. It shall be isolated from bottom floor panel through 25 mm thick heavy duty Treated for Fire (TF) quality expanded polystyrene or polyurethane foam. Drain pan shall extend beyond the coil. 3.2.4 Casing shall be of air-tight construction and sufficiently rigid to exclude vibrations, throughout the working capacity range of the AHU.

5.6.4

FILTERS

5.6.4.1 Pre-filter Each unit shall be provided with a factory assembled filter section containing air filters of washable synthetic fibre or High Density Polyethylene (HDPE) media having 18G GSS frame. The media shall be supported with HDPE mesh on one side and aluminium on the other side. Filter banks shall be easily accessible and designed for easy withdrawal and replacement of filter cells. Filter bank frame work shall be fully sealed and constructed from GSS. The efficiency of the filters shall be 90% down to particle size of 20 microns as per IS 7613. 5.6.4.2 Fine-filter 335

Flanged microvee filters with HDPE filter media shall be provided. The filter frame and filter bank framework shall be of 18G GSS construction with neoprene rubber gasket. The efficiency of the filters shall be 99% down to particle size of 5 microns as per IS 7613. Preferably, fine filters shall be located at the downstream side of fan section inside the AHU. 5.6.4.3

HEPA filter Flanged HEPA filters having cold Di-Octyl-Phthalate (DOP) test efficiency of 99.97% down to particle size of 0.3 microns, shall be located at the downstream side of fan section inside the AHU. HEPA filters made of sub-micron glass fibre paper shall be designed for velocities of 1.25 metres per second. The filter frame work shall be of aluminium and filter bank shall be of GSS construction. Three (3) mm thick neoprene rubber gaskets shall be provided to prevent any air leakage.

5.6.5

COOLING COILS AND HEATING COILS

5.6.5.1 Cooling and heating coils shall have 12.5 to 15 mm diameter tubes of minimum 24G thickness with sine wave aluminium fins firmly bonded to copper tubes assembled in zinc coated steel frame of 1.5 mm thick. Face and surface areas shall be such as to ensure rated capacity from each AHU. The coil face air velocity across the coil shall not exceed 2.54 metres per second for cooling coil and 4 metres per second for heating coil. The coil shall be pitched in the AHU casing to ensure proper drainage. Each coil shall be factory tested to 21 Kg/cm2(g) air pressure under water. Tube shall be mechanically expanded for minimum thermal contact resistance with fins. Fin spacing shall be 4 to 5 fins per cm. Coil piping shall be extended through the casing wall approximately 150 mm and provided with 1034 kPa raised face flange connection. In case, multiple coil sections are provided, the coil inlet and outlet connections shall be headered inside or outside the AHU and only one (1) common inlet and outlet connections shall be provided for the coils outside the AHU. The companion flanges with gaskets, nuts and bolts shall be provided for piping connections. Pipe extension shall be IS 1239 heavy class. A packing gland is required at the casing wall to provide an air tight seal around the opening. Coil piping connection side shall be determined by final layout and design arrangement. 5.6.5.2 Coils shall be sealed in polythene bags and packed in crates properly. Coils with damaged fins shall not be accepted. 5.6.6

FAN SECTION

5.6.6.1 Fans shall be Double Width Double Inlet (DWDI) centrifugal type. Fans shall have forward curved or backward curved blades as specified in data sheet A. The fan speed shall not exceed 1000 RPM and fan outlet air velocity shall not be more than 11 metres per second. Fan casing and impeller shall be made of galvanised steel or epoxy painted carbon steel. Fan shaft shall be made from EN 8 steel and supported in self aligning plummer block, operating at less than 75% of first critical speed with grease lubricated bearings. Impellers and pulleys shall be individually tested and precision balanced statically and dynamically. Fans shall be tested for performance at manufacturer‟s works as per AMCA 210 and at site. 5.6.6.2 Motors shall drive heavy duty V-belt, constant speed, fixed pitch drive sheaves, selected at 1.5 service factor with a minimum of two (2) grooves to prevent start-up slippage and pre336

mature belt failure. Motors shall be specially designed for quiet operation and motor speed shall not exceed 1440 rpm. Belts shall be of oil resistant type. Belt guard shall be provided with enough space on motor side to fit in the largest pulley for maximum speed. Also provision shall be made for adjusting the motor side of the belt guard in relation with the motor adjustment. In case of single skin AHU, motor shall be mounted outside the casing on slide rails for easy belt tensioning. Fan and motor shall be mounted on aluminium alloy or galvanised steel base frames. Isolation shall be provided from the AHU casing by combination spring and rubber anti-vibration mounts having a 70 to 80% vibration dampening efficiency and flame retardant, water proof neoprene impregnated flexible connection on fan discharge. 5.6.6.3 In case of double skin AHU, motors shall be mounted inside the casing on slide rails for easy belt tensioning. The entire fan and motor assembly shall be mounted on a common deep section aluminium alloy or galvanised steel base frame. Isolation shall be provided from the AHU casing by combination spring and rubber anti-vibration mounts having a 70 to 80% vibration dampening efficiency and flame retardant, water proof neoprene impregnated flexible connection on fan discharge. 5.6.7

MIXING BOX Mixing box shall be complete with fresh and return air dampers. Mixing box shall be provided whenever the return air is ducted back to the AHU.

5.6.8

DAMPERS Dampers shall be opposed blade type. Blades shall be made of double skin airfoil extruded aluminium sections with integral gasket and assembled within a rigid extruded aluminium alloy frame. All linkages and supporting spindles shall be made of aluminium or nylon, turning in teflon bushes. In case of automatic dampers, sealed ball bearings shall be provided, in place of teflon bushes. Manual dampers shall be provided with a bakelite knob for locking the damper blades in position. Linkages shall be extended for motorised operation if specified in data sheet A. Damper frames shall be sectionalised to minimise blade warping. Air leakage through dampers when in the closed position shall not exceed 1.5% of the maximum design air volume flow rate at the maximum design air total pressure.

5.6.9

GENERAL

5.6.9.1 Each AHU shall be provided with manual air vent at high point in cooling and heating coil and drain plug in bottom of the coil. Vent and drain shall be provided with 15 mm NB gate valves. Condensate drain line size shall be 40 mm NB. 5.6.9.2 Shop coats of paint that have become marred during shipment or erection shall be cleaned off with mineral spirits, wire brushed and spot primed over the affected areas, then coated with paint to match the finish over the adjoining shop painted surface. (Eliminator plates, if specified in data sheet A, shall be of aluminium alloy or PVC fill with three (3) bends. Blow through AHU shall have diffuser section at the downstream of fan. The diffuser provided shall be of 18G perforated aluminium sheet having minimum 50% free area. Ribbed neoprene rubber pads as vibration isolators shall be provided for AHUs.)

5.6.9.3 Power and control cabling for fan motors and any other electric consumers inside the AHU shall be provided by the AHU CONTRACTOR and the same shall be brought outside the 337

AHU and terminated in junction boxes provided by the AHU CONTRACTOR. Lockable on/off push button for each motor shall be provided outside the AHU. 5.6.9.4 Marine lights shall be provided in AHU sections for maintenance, if specified in data sheet A. One (1) light switch shall be provided on the exterior of the AHU to control all the fixtures. The lighting switch shall be completely pre-wired to a junction box on the top of the AHU. Lighting wire shall be carried out with PVC insulated, 600 volts grade, 2.5 mm2 stranded copper conductor wires. The purchaser shall provide 240V, single phase supply to the junction box.

FILE NAME:M4-122-03-Rev-R2(1).DOCX Proprietary rights of the information contained herein belong to Tata Consulting Engineers Limited (TCE). information is intended to be used for the mentioned purpose/project only. In case of misuse of information arising thereof, cost and consequence will be on the party misusing the information.

MINIMUM NUMBER OF STEPS REQUIRED FOR ELECTRIC STRIP HEATER : THREE (3)

67.

DEHUMIDIFIED AIR QUANTITY: (AS PER AHU TABLE) M3/HR

68.

STATIC PRESSURE: (SEE SHEET 5) MMWC

69.

ENTERING DRY BULB TEMPERATURE: (AS PER AHU TABLE) ○ C

70.

ENTERING WET BULB TEMPERATURE: (SEE SHEET 5) ○ C

71.

LEAVING DRY BULB TEMPERATURE: (AS PER AHU TABLE) ○ C

72.

LEAVING WET BULB TEMPERATURE: (AS PER AHU TABLE) ○ C

73.

CHILLED WATER / BRINE FLOW: (AS PER AHU TABLE) CMH

74.

CHILLED WATER / BRINE INLET ○ TEMPERATURE: C

75.

CHILLED WATER / BRINE OUTLET ○ TEMPERATURE: C

76.

NOISE LEVEL AT ADISTANCE OF 1.5 METRES: 65 dB(A)

MANUAL / PNEUMATIC / ELECTRIC

64.

REFER TCE.M4-981 „ SCHEDULE OF ESSENTIAL & RECOMMENDED SPARES‟

65.

REFER TCE.M4-982 „ SCHEDULE OF MAINTENANCE TOOLS & TACKLES‟

66.

77. 78.

TESTS & INSPECTION

O

COST LOADING & SPARES & MAINTENANCE TOOLS & TACKLES PENALTY

TEMPERATURE :

PERFORMANCE GUARANTEES

UNIT

ITEM

REFER TCE.M4-983 „ SCHEDULE of START-UP & COMMISSIONING SPARES‟

79.

POWER CONSUMPTION;

RS/KW

80.

CHILLED WATER/BRINE CONSUMPTION: RS/M3/HR

81. 82.

TESTS & INSPECTION

SL NO.

83. 84.

341

AHU DETAILS: Sl. No

1

AHU for

Treated Fresh Air

Tag Nos.

Qty

Cooling Capacity

811AHU-

Nos

TR

G01

2

5.5

Entering Air temperature DBT WBT °F

°F

Leaving Air Fan Static temperature Fan capacity Pressure DBT WBT °F

BIDDER TO SPECIFY

°F

CFM

mm WC

2600

50

342

5.7 5.7.1

CONDENSING UNITS FOR AIR-CONDITIONING APPLICATION SCOPE This specification covers the general design, materials, construction features, manufacture, shop inspection and testing at manufacturer's works, delivery at site, handling at site, installation, testing, commissioning and carrying out performance test at site and handing over of Condensing Units of capacities 5 TR to 100 TR used for Air Conditioning application . Type of refrigerant shall be R 22 or R 134a.

5.7.2

CODES AND STANDARDS The design, materials, manufacture, inspection, testing and performance of Condensing Units shall comply with all currently applicable statutes, regulations, safety codes and standards in the locality where the equipment is to be installed. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility. In particular, the Condensing Units shall conform to the latest edition of the following standards:

Standard for Method of Measuring Machinery Sound within an Equipment Space

ISO 1940

Mechanical Vibration - Balance Quality Requirements of Rigid Rotors

CONSTRUCTION FEATURES

5.7.3.1 COMPRESSOR The compressor shall be either hermetic / semi hermetic reciprocating, screw or scroll type as specified in data sheet A and shall be mounted on vibration isolators. Necessary crankcase heaters shall be provided in the compressor for capacities exceeding 10 TR.

343

5.7.3.2

CONDENSER Water Cooled Condenser shall be of shell & tube type with carbon steel shell and integrally finned copper tubes as per TEMA-B. Air Cooled Condenser shall be with copper tubes and aluminium fins with low noise fans. Speed of the fans shall not exceed 960 RPM for fans with impeller diameter above 450 mm & 1440 RPM for fans with impeller diameter 450 mm and less. The impeller shall be statically and dynamically balanced. The air cooled condenser motor shall have IP:55 or better protection.

5.7.4.3 Piping shall be designed for not less than the internal pressure given in the table.

REFRIGERANT NUMBER

REFRIGERANT NAME

R 22

Monochloro difluoro methane

R 134a

Tetrafluoro ethane

MINIMUM INTERNAL DESIGN PRESSURE HIGH PRESSURE SIDE LOW PRESSURE (Kg/cm2g) SIDE (Kg/cm2g) WATER AIR COOLED COOLED

20

25

13/full vacuum

13.5

17.5

8.55/full vacuum

5.7.4.4 Test pressure for piping shall be 1.1 times of design pressure. The pressure shall be gradually increased until a

gauge pressure which is the lesser of one-half of the test pressure or 1.75 Kg/cm2g is attained and preliminary leak checks shall be carried out. Thereafter, the pressure shall be gradually increased in steps until the test pressure is reached. The pressure shall then be reduced to the design pressure and leakage examination shall be made. The design pressure shall be maintained for 48 to 72 hours. A pressure relief valve/device shall be provided on test pressure line having a set pressure slightly above the test pressure. Nitrogen shall be used as test medium. Oxygen or any combustible mixture of gases shall not be used within the piping for testing. Water or water solutions shall not be used as a test medium.

344

5.7.4.5 Vacuum testing shall be done for medium vacuum of around 40 mm Hg absolute and held with vacuum pump in operation for at least 4 hours. Thereafter unit shall be sealed and vacuum held for at least 12 hours. Vacuum break shall be done using refrigerant and pressure raised to standing pressure in refrigerant cylinder.

5.7.4.6 Provision for interlock in the control panel shall be provided such that compressor can start only after starting the air handling fan of evaporator unit. Provision shall also be made to interlock the compressor with condenser water circulation pump or the air cooled condenser fan motor / air flow switch. Safety devices such as high/low pressure (HP/LP) cut out, hermetic motor winding thermostat etc. shall be provided. HP cut out shall be manual reset type while LP cut out shall be auto reset type.

5.7.4.7 The water cooled unit shall be factory piped with adequate charge of refrigerant and oil. The refrigerant piping and refrigerant charging for air cooled units shall be carried out at site. Refrigerant and oil shall be supplied along with the unit till the unit is handed over to the PURCHASER.

5.7.5

ELECTRICAL

5.8.5.1 A terminal box suitable for connecting external 3 phase, 4 wire cable shall be provided. 5.8.5.2 The unit shall be provided with single phase preventer. 5.8.5.3 The control panel shall be complete with starters for compressor and condenser fan/pump motors and shall be prewired. 5.8.5.4 The wiring between the Condensing Unit and Indoor Unit shall be carried out at site. 5.8.5.5 Control panel shall be suitable for ambient temperature of 50OC. 5.7.6

PAINTING As the Condensing Units (CNU) are normally located outside, painting used shall be of corrosion resistant type and shall be as per manufacturer's standards.

5.7.7

GENERAL

5.8.7.1 The compressor and condenser of the condensing unit shall have a common base frame. 5.8.7.2 The condensing unit shall be mounted on suitable vibration isolators.

345

5.7.8

PERFORMANCE GUARANTEES Performance parameters to be guaranteed by the Contractor and tolerances permitted shall be as indicated in Section C and/or Data Sheet - A. The Bidder shall confirm acceptance of these by indicating values in Data Sheet - B. Condensing Units or any portion thereof is liable for rejection, if it fails to give any of the guaranteed performance parameters.

346

DATA SHEET - A SL. NO.

ITEM

1.

DESIGNATION

2.

NUMBERS OFFERED

3.

TAG NUMBERS

4.

MAKE /MODEL NUMBER

5.

PLACE OF MANUFACTURE

6.

NOMINAL CAPACITY OF EACH CONDENSING

2NOS

UNIT(CNU)

TR

55

7.

CAPACITY OF EACH CNU AT SPECIFIED DESIGN CONDITION

TR

5.5

8.

REFRIGERANT

9.

OVERALL SIZE OF EACH CNU

10.

CLEARANCE REQUIRED ON ALL SIDES OF EACH CNU

mm

11.

OPERATING WEIGHT

Kg

12.

NOISE LEVEL AT 1.86 M DISTANCE :

12.1

COMPRESSOR

dBA

12.2

CONDENSER FAN(IF AIR COOLED)

dBA

13.

NUMBER OF REFRIGERATION CIRCUITS/ CNU

Nos.

14.

TOTAL INPUT POWER AT SPECIFIED DESIGN

R 134a Lx Dx

CONDITIONS PER CNU 15.

TYPE OF VIBRATION ISOLATORS

16.

TYPE , MAKE AND MODEL NUMBER

17.

NUMBER OF COMPRESSORS PER CNU

18.

PLACE OF MANUFACTURE

19.

SUCTION TEMPERATURE

20.

SUCTION PRESSURE

21.

CONDENSING TEMPERATURE

H

mm

x FRONT

x

BACK

SIDES

TOP

kW

Nos. O

1 NO

C

Kg/cm2 g O

C

AMBIENT

347

COMPRESSOR (CONTD.) CONDENSER

Kg/cm2g

22.

CONDENSING PRESSURE

23.

OPERATING SPEED AT SPECIFIED DESIGN CONDITION

24.

CAPACITY AT SPECIFIED DESIGN CONDITION PER COMPRESSOR

25.

BKW AT SPECIFIED DESIGN CONDITION PER COMPRESSOR

26.

MOTOR RATING PER COMPRESSOR

27.

CAPACITY CONTROL AVAILABLE

28

IN STEPS OF

29.

TYPE , MAKE AND MODEL NUMBER

30.

WATER COOLED CONDENSER

30.1

NUMBER OF CONDENSERS PER CNU

30.2

HEAT REJECTION CAPACITY AT SPECIFIED DESIGN CONDITIONS PER CONDENSER

KCal/Hr

30.3

TOTAL HEAT REJECTION CAPACITY AT SPECIFIED DESIGN CONDITIONS PER CNU

KCal/Hr

30.4

CONDENSER COOLING WATER FOULING FACTOR

HR.SQ FTOF/ BTU

30.5

COOLING WATER FLOW RATE/ CONDENSER

30.6

COOLING WATER INLET TEMPERATURE

O

C

30.7

COOLING WATER OUTLET TEMPERATURE

O

C

30.8

WATER VELOCITY IN TUBES

M/Sec

30.9

WATER SIDE PRESSURE DROP

Kg/cm2

31.

AIR COOLED CONDENSER

31.1

NUMBER OF CONDENSERS PER CNU

31.2

HEAT REJECTION CAPACITY AT SPECIFIED

RPM TR BKW kW YES / NO

Nos.

M3/Hr

Nos. KCal/Hr

DESIGN CONDITIONS PER CONDENSER 31.3

TOTAL HEAT REJECTION CAPACITY AT SPECIFIED DESIGN CONDITIONS PER CNU

KCal/Hr

348

MAKE OF ACCESSORIES PERFORMANCE GUARANTEE

31.4

MAXIMUM PERMISSIBLE DISTANCE BETWEEN CNU AND INDOOR UNIT

M

31.5

CONDENSER FANS

31.5.1

NUMBERS IN EACH CONDENSER

31.5.2

CAPACITY OF EACH FAN

31.5.3

STATIC PRESSURE

31.5.4

IMPELLER MATERIAL

31.5.5

BRAKE POWER OF EACH FAN

kW

31.5.6

INPUT POWER OF EACH FAN

kW

31.5.7

MOTOR RATING OF EACH FAN

kW

32.

HIGH AND LOW PRESSURE CUT OUTS

33.

THERMOSTAT

34.

SOLENIOD VALVE

35.

SINGLE PHASE PREVENTOR

36.

STARTERS

37.

VIBRATION ISOLATORS

38.

CONTROL PANEL

39.

CAPACITY OF EACH CNU AT DESIGN CONDITIONS

TR

40.

TOTAL POWER INPUT AT DESIGN CONDITIONS

kW

41.

NOISE LEVEL AT 1.86 M DISTANCE FROM CNU

dBA

42.

CONFIRM THAT UNITS CAN BE INSTALLED,

VERTICAL

TOTAL

M3/Hr mmWC

GENERAL

OPERATED AND SERVICED IN AVAILABLE PLANT ROOM SPACE 43.

CONFIRM THAT UNITS ARE SUITABLE FOR SPECIFICIED VOLTAGE AND FREQUENCY

44.

YES/NO

YES/NO

PERFORMANCE CURVE/RATING CHARTS ENCLOSED.

YES/NO

349

5.8

APPROVED MAKE LIST OF HVAC EQUIPMENTS -

-

-

-

-

NOTE: All materials and products shall conform to the relevant standards and shall be of approved make and design. A list of manufacturers/ vendors is given separately herein below for guidance. The Engineer shall give the approval of a manufacturer/ vendor/ only after review of the sample/ specimen. In case the same is not available in the market or in case of change in trade name, equivalent makes/ re-designated manufacturer then an equivalent approved make shall be used with the approval of Employer/ Engineer. The complete system and installation shall also be in conformity with applicable Codes & Standards and Tender specifications. Only “First” class quality materials shall be used. Employer reserves the right to choose any of the approved make / vendors as per this list. In case of products not indicated in this list, bis marked products shall be preferred. Specification of manufacturer‟s item shall be checked against tender item / specifications before selecting any product or brand name. In case of any discrepancy, tender item/ specifications shall prevail, and any such brand of item shall not be used which is not conforming to tender specifications even if it is listed in this list. For use of material from a bis listed/ certified manufacturer, the contractor shall furnish a copy of the BIS certificate to Employer before procuring the material. In case non-availability of any item/ material among approved manufacturers/ brands at a particular site/ region, alternate manufacturers/ brands conforming to BIS/ BS etc. shall be used subject to approval by Employer. In case of non-availability of any manufacturer among approved manufacturers at a particular site/ region, alternate manufacturer‟s name shall be proposed along-with required credentials for Employer‟s approval. In case of any item/ product neither covered in this list nor having A BIS specifications, the contractor shall submit the proposed item/ product along-with technical details/ specifications (as per bid), test certificates etc. And other credentials of the manufacturer for Employers approval.

350

LIST OF APPROVED MAKES FOR PRODUCTS AND MATERIALS FOR HVAC WORKS ARE INDICATED IN THE TABLE BELOW. HOWEVER, ANY OTHER MAKE WHICH IS EQUIVALENT AND MEETING THE TENDER SPECIFICATIONS ARE ALSO ACCEPTABLEWITH PRIOR APPROVAL OF THE ENGINEER S.No.

This section covers the requirements for compressed air generation facilities to be supplied at technical centre at Pudi. This system package shall be modularised / pre-assembled as much as possible, aiming for the shortest construction period.

6.1.2

EQUIPMENT AND SERVICES TO BE PROVIDED BY CONTRACTOR

The equipment to be supplied and erected under this specification are shown in the flow diagram enclosed with this specification, as detailed in section Schedule of quantities and these shall be in accordance relevant Data sheet A of this section. Any item which may not have been specifically mentioned herein but are needed to complete the equipment / system shall also be treated as included and the same shall also be furnished and erected, unless otherwise specifically excluded as indicated.

6.1.3

ENGINEERING / DESIGN a) Supply of engineering information for interface points with other piping. b) Operation philosophy and control logic for instrumentation and controls. c) General arrangement and equipment layout drawings of compressors, receiver and air drying plant in compressor room. d) P&ID of compressor system.

6.1.4

SUPPLY ALL MATERIALS TO SITE INCLUDING, BUT NOT LIMITED TO a) Two nos (1W+1S ) motor driven, lubricated air cooled screw compressor inbuilt with refrigerant type dryer, capable of delivering 170CFM (FAD) each at a discharge pressure of 8.5 Kg/cm² (g) with associated accessories as per enclosed datasheets. 357

b) One set of filters consisting of pre-filter and fine filter to restrict oil carry over to 1 mg/m3. Differential pressure gauge with root isolation valve shall be provided at appropriate locations. c) One no. Vertical air receiver as per enclosed datasheet with all accessories having capacity of 1 M³. Receiver shall be provided with two (2) suitably sized safety valves to relieve the full compressor discharge capacity and shall be set at a pressure 1.25 times the operating pressure. Receivers shall be provided with one no. pressure indicator and auto drain trap assembly. d) All instruments for the compressor as indicated (but not limited to) in attached flow diagram & data sheets required for proper operation & monitoring of the compressor along with all instrument impulse piping, fittings and erection hardware. e) Completely wired microprocessor based panel along with operator interface unit with LCD screen with push buttons for compressor operation and all necessary accessories shall be supplied fully wired for each compressor for load-un-load / start-stop & other controls for the compressor along with complete earthing. f) All instruments for the air dryer required for proper operation & monitoring of the air dryer along with all instrument impulse piping, fittings and erection hardware. g) Completely wired skid mounted microprocessor based panel for the air dryer for operation and monitoring along with complete earthing. h) Control and instrumentation cables for connection between instrument / equipment/ MCC and the control panels for the compressor & air dryer along with all cable trays, conduits, glands, termination accessories etc.. i) One lot of base plates, foundation bolts, nuts and washers etc. required for each equipment j) Counter flanges with bolts, nuts, washers and gaskets for all equipment at all terminal points of equipment covered under Contractor‟s scope of supply. k) First fill of all lubricants and consumables l) One set of commissioning and start – up spares. (Price for the same shall be included in the total quoted price only).

358

m) One set of recommended spares for 2 years of trouble free operation. (Contractor shall list the recommended spares and furnish the unit rates separately) n) One set of recommended maintenance tools and tackles. (Contractor shall list the same and furnish the unit rates separately) o) Painting p) Installation, operation and maintenance manual for the complete system

EQUIPMENT & SERVICES TO BE PROVIDED BY CONTRACTOR. The following are the equipment and services that shall be provided contractor: a) Supply & laying of power cable up to the vendor panel shall be done by electrical works contractor. b) Earthing pits and the earthing cables from the compressor control skid /dryer control panel to the earthing pits. c) All inter-connecting piping with valves, fitting & specialities, as indicated on flow diagram TCE.10106A-6047-PI-60684. d) Civil construction, buildings, equipment foundations by civil contactor. e) Electrical trenches and drain by civil contactor.

359

6.2

CODES AND STANDARDS

All equipment, systems and works covered under this specification shall comply with all currently applicable statutes, regulations, standards and safety codes in the locality where the equipment will be installed. All equipment and systems shall comply in all respects with requirements of latest editions of codes and standards as indicated in this specification. In the event of any conflict between the codes and standards referred to in the specification and the requirements of this specification, the more stringent of this requirement shall govern. a) ASME SEC. VIII DIV.1-2015 b) IS 5456:2006

SPECIFIC REQUIREMENTS / INSTRUCTION TO CONTRACTOR All equipment supplied shall have capacities not less than those specified in the in the specification and necessary test certificates shall be furnished in this regard. However, if the CONTRACTOR feels that higher capacity equipment is required meet guarantee requirements, he should offer the same and substantiate the same by calculations. Any conflict between the requirements of this section and related specification, codes, standards and other documents, shall be referred to Project Manager‟s for clarification. Fabrication of package unit equipment shall be executed in a controlled manner. This means that all executed checks, tests and inspections are documented in the manufacturing report Equipment design shall be aimed at maximum standardization of components and subassemblies to ensure lowest possible inventory of replacement of parts. The equipment within the package unit shall be easily accessible for operation and maintenance. The motor rating indicated in the bid shall be final and the CONTRACTOR is not permitted to change this after the award of contract. 360

6.3.7 6.3.8

6.3.9 6.3.10

6.3.11

6.3.12

6.3.13

6.3.14

6.3.15

6.4 6.4.1 6.4.2 6.4.3

6.4.4

6.4.5 6.4.6 6.4.7

If required, vibration isolators, mounting / installation structural frames for all equipment shall be part of the CONTRACTOR‟s scope of work. The CONTRACTOR shall quote unit rates for each type of equipment viz. Compressors, dryers and receivers etc. so that if Employer desires to add or delete the same from CONTRACTOR‟s scope of work, then the total price shall be adjusted based on the unit rates furnished by the CONTRACTOR. Two nos of compressors (1W+1S) of 170 CFM(FAD) capacity each are in operation at present. The scope of work shall also include guarantee for trouble free operation of the complete system and equipment/accessories therein for a period of 18 months from the date of supply at site OR 12 months from date of successful commissioning of the system, whichever is earlier. This guarantee shall also include overall performance guarantee of the entire` system to achieve design conditions stated in specification along with all necessary safety and statutory requirements. During the guarantee period the CONTRACTOR shall rectify free of cost of all defects which may develop due to faulty design, material, construction and workmanship inclusive of free replacement of defective parts. During the guarantee period the parts of the equipment requiring repairs or replacement shall be fitted at site by the CONTRACTOR such that the functioning of the system is not compromised for any reason whatsoever. All expenses involved in fulfilling the above guarantee obligations like replacement of spares, consumables, deputation of service experts, their travel/lodging/boarding shall be borne by the CONTRACTOR. Damages occurred to ceiling/floors/walls or any other parts of the building construction/maintenance shall be made good free of cost with approved fire rated materials failing which, the cost shall be debited to the CONTRACTOR.

SPECIFIC ELECTRICAL REQUIREMENT Electric supply for motors covered under this package shall be made at 415 V, 3 phase by EMPLOYER. CONTRACTOR shall carryout all interconnecting control cabling inside the compressed air system panel. Necessary cable conduits / trays shall be provided by CONTRACTOR. Control cables shall be stranded copper conductor PVC insulated and extruded PVC inner sheathed, galvanised steel stripwire armoured overall extruded PVC outer sheathed conforming to latest IS. Employer will provide only power supply (415 V, 3 Ph) at one point. Further distribution to each panel / motor shall be by CONTRACTOR. Any further stepping down of supply shall be done by CONTACTOR inside the control panel. CONTRACTOR to include supply and installation of Star-Delta feeder for the compressor in the compressor panel. The Star-Delta feeder shall include the starter, over-load relay, CTs ammeter and all necessary auxiliary relays, controls and on/off/trip indications on the panel. Earthing for all equipment shall be by EMPLOYER.

361

6.5

SPECIFIC REQUIREMENT OF I & C SYSTEM

6.5.1

This specification shall be read in conjunction with the data sheets, enclosed as part of of this Section.

6.5.2

I&C SYSTEM FOR COMPRESSOR

6.5.2.1 The Air Compressor Package Unit shall be supplied complete with all instruments and control equipment/systems, both field and panel mounted. It shall include but not be limited to the following : (a) Pressure indicators as per data sheet for : i. Discharge of each compressor ii. Each air receiver pressure iii. Lube oil pressure (b)

Pressure Switches as per data sheet for Lube oil pressure low.

(c)

Pressure transmitter as per data sheet for Pressure transmitter on each air receiver for: i. Air receiver pressure high & low alarms ii. Loading/unloading of each air compressor iii. Auto start/stop action of each compressor

(d)

Thermometers as per data sheet or : i. Air temperature for inter stage of each compressor (where multistage compressors are required). ii. Air temperature at the discharge of each compressor. iii. Air temperature in outlet of the dryer

(e)

Temperature Switches as per data sheet No. for : i. Air temperature at discharge of each compressor high ii. Air temperature after cooler high iii. Lube oil temperature high

(f)

Safety Relief valves as per data sheet for air receiver pressure very high.

6.5.2.2 Control Panel Microprocessor based control panel shall be provided for compressor. It shall be provided with operator interface unit (OIU) with 4 line LCD display. It shall display all the process parameters and alarms on the screen. Alarms shall be provided with audible and visual 362

indication. Push button shall be provided for start/stop operation of the dryer. All logic and interlocks for sequential operations shall be programmed in the controller unit.

The panel shall be prefabricated type with enclosure protection of IP 52 as per IS 13947. The panel shall be made of CRCA cold rolled sheet of 2mm thickness. The panel shall be painted with exterior colour 631 of IS-5 & interior paint shall be glossy white. 3 pin receptacle for 230 V AC, 1P, 50 Hz shall be provided inside the panel. All internal wiring shall be carried out with 1100V grade, stranded tinned copper conductors with PVC insulation. The panel shall be provided with a proper earthing bus made of copper securely fixed along the inside base of the panels. This bus shall be typically of 25 mm wide and 6 mm thick of copper.

(a)

Each compressor unit shall be provided with necessary controllers for the safe & reliable operation of the compressor.

(b)

A two position selector switch shall be provided on the control panel for selection of the compressor AUTO/MANUAL

(c)

Each compressor panel shall be provided with a three position selector switch marked Auto-Off-On for the following functions : i.

Auto -

The compressor shall be selected as „Working‟ in load / unload mode.

ii. Off

Stops the respective motor.

iii. On

For manual start of the respective compressor by push buttons with load / unload regulation.

(d)

Pushbuttons shall be provided on the front facia of the control panel for manual start/stop operation of the compressor. An emergency stop pushbuttons shall also be provided.

(e)

One potential free contact will be made available at the terminals of the each compressor control panel for remote alarm under trip condition.

(f)

The control system shall permit operation of each compressor in either of the following two regulations: 363

(g)

i.

Continuous Run-Load-Unload Regulation.

ii.

Automatic Start-Stop Regulation.

Under continuous Run-Load-Unload Regulation, the drive motor shall run continuously while the compressor shall be loaded at pre-set (adjustable) cut-in pressure as the receiver pressure falls and unloaded at a higher pre-set (adjustable) cut-out pressure, as the receiver pressure rises. With automatic Start-Stop Regulation, the drive motor shall automatically start at pre-set (adjustable) cut-in pressure as the receiver pressure falls and automatically stop at a pre-set (adjustable) higher cut-out pressure as the receiver pressure rises.

(h)

With either system, the compressor shall always be unloaded when the drive motor starts. The unloaders shall keep the compressor unloaded till the drive motor comes to full speed.

(i)

Following are the minimum alarm annunciation required to be provided on the operator interface unit screen. In addition to the alarms mentioned below vendor shall provide the necessary alarms for safe operation of compressors: i.

Tripping of individual air compressors

ii.

Each air receiver pressure high

iii.

Each air receiver pressure low

iv.

Lube oil pressure low

v.

Air temperature at discharge of inter stage of each compressor high

vi.

Air temperature at discharge of each compressor high

vii.

Air temperature after each after cooler high

viii. Lube oil temperature high (j)

1 no. of hooter shall be provided on the panel for the sound identification of the Alarm condition. Facility for the Test / Acknowledge / Reset for Alarms shall be provided on the PLC panel.

(k)

All inter cubical and internal wiring for the panel shall be carried out with 1100V grade, stranded tinned copper conductors with PVC insulation.

364

6.5.2.3 The panel shall be provided with a proper earthing bus made of copper securely fixed along the inside base of the panels. These buses shall be typically of 25 mm wide and 6 mm thick of copper. 6.5.2.4 Operator Interface Unit Unless otherwise specified all set points, control parameters, alarm limits and timers shall be adjustable through the Operator Interface Unit (OIU) with suitable password protection. (a)

6.5.2.5 INSTRUMENT POWER SUPPLY The power supply made available for instrumentation system for both compressor shall be 230V AC. Converters or power supply units required to derive the necessary operating voltages other than 230V AC for the instrumentation system shall be in the scope of contractor. MCBs shall be provided in the panel for each power supply distribution feeder to field & panel mounted instruments and PLC. 6.5.2.6 CABLES Cabling from control panels to electrical panel and cabling between instruments & panels supplied by the Contractor shall be by Contractor. Necessary cable trays, conduits shall be provided by contractor. The specifications for the cables shall be as per data sheet. 6.5.2.7 INSTALLATION & COMMISSIONING CONTRACTOR's scope of work includes, erection of instruments and control panel, instrument cabling, loop checking and commissioning. All instruments shall be erected in such a manner that they are easily read and maintenance can be carried out easily without shutting down the plant. Prior to guarantee run of the plant, all the instruments shall be recalibrated and the results shall be recorded. Erection of instruments shall be carried out as

365

per the CONTRACTOR's instrument installation drawings after getting Project Manager's / Employer‟s approval. 6.5.2.8 TESTING & INSPECTION All the instruments & panels shall be tested and calibrated at manufacturer's works in an approved manner. Inspection shall be carried out in the presence of Employer‟s inspector. All test certificates for testing instruments shall have calibration certificates from approved test house, valid for minimum 6 months.

6.6

GUARANTEES AND PERFORMANCE REQUIREMENT

6.6.1

GENERAL The compressed air system shall perform satisfactorily to meet the guarantee requirements specified to the entire satisfaction of the EMPLOYER / ENGINEER.

6.6.2 COMPRESSED AIR SYSTEM i. The CONTRACTOR shall guarantee the capacities of various equipment as specified in this section and schedule of quantities. ii.

Allowable tolerances on dew point temperature at atmospheric pressure of compressed air at battery limit shall be:

v.

Allowable noise level measured at a distance of 1.5 metres from the source in any direction:

vi. 6.6.3

(-) Anything, (+) Zero

(+) Zero , (-) Anything

The above allowable tolerance requirements are excluding instrument tolerances. POWER CONSUMPTION  Tolerance on Power consumption:

(+) Zero (-) Anything

366

6.7

ACCEPTANCE TEST

6.7.1

After the entire installation work has been completed, the CONTRACTOR shall make all required adjustments until all guaranteed performance requirements are met. All instruments, services required for the above tests shall be furnished by the CONTRACTOR. The test reports shall be handed over for EMPLOYER‟s approval before handing over the plant.

6.7.2

If the stipulated performance requirements are not fulfilled, the CONTRACTOR shall make good the deficiency by providing it in every case, by altering and/ or replacing the parts or the whole equipment / system free of charge to the EMPLOYER immediately. All rejected equipment shall be removed from the site at CONTRACTOR‟s expense.

TENDER EVALUATION AND PENALTY FACTOR Tender Evaluation a) The CONTRACTOR shall comply with all systems / parameters wherever they are specified in specification and in data sheets A . Evaluation factor as indicated in para below for power consumption shall apply. The evaluation factor shall be applicable to the differential power consumption of all installed equipment, calculated with the lowest quoted parameter as the base. The CONTRACTOR shall indicate under section schedule of quantities the guaranteed power consumption for each equipment separately. b) Deviation from the specifications, if acceptable to the EMPLOYER insofar as practicable will be converted to rupee value and added to the bid price to compensate for the deviation from the specification. In determining the rupee value of the deviations, the EMPLOYER will use the parameters consistent with those specific in the documents and specifications and other information as necessary and available to the EMPLOYER.

367

6.10 MAINTENANCE REQUIREMENTS 6.10.1 In order to carry out preventive maintenance, it should be possible to readily disassemble, repair, re-assemble the equipment in the shortest period and to attend to any defect by a minimum disassembly. 6.10.2 The CONTRACTOR shall furnish one complete set of any special maintenance tools required for normal maintenance of equipment. The prices for the same shall be indicated in– Schedule of prices and delivery. 6.10.3 The CONTRACTOR shall confirm that space shown for the equipment is adequate from point of view of access, easy maintenance and for day to day operation. 6.10.4 All system must have convenient maintenance characteristics including : a) Minimum disturbance to production during preventive maintenance. b)

Easy access to replacement part which can be installed by personnel with minimum skill.

6.11 SUMMARY OF DATA TO BE FURNISHED ALONG WITH BID AND AFTER ACCEPTANCE OF PURCHASE ORDER

The CONTRACTOR shall ensure the following documentation are prepared and submitted to EMPLOYER for his review / record. 6.11.1 ALONG WITH BID Sl. No. 1.0

Details Description of the systems offered along with catalogues, leaflets, drawings, etc.

6.11.3 FINAL DOCUMENTS 6.11.3.1 CONTRACTOR shall submit the copies of operation and maintenance manuals well before the despatch of the equipment. The manual shall be in sufficient detail with step by step instructions to enable others to inspect erect, commission, maintain, dismantle, repair, reassemble and adjust all parts of the equipment. Each manual shall also include a complete set of approved as built drawings together with performance / rating curves / charts of the equipment, maintenance schedule and test certificates wherever applicable. 6.11.3.2

Quality assurance documentation specific for the project.

6.11.3.3

PIPING MATERIAL SPECIFICATION

370

BUTT WELDING SW

SOCKET WELDING

CS

CARBON STEEL

SS

STAINLESS STEEL

CI

CAST IRON

CL

CLASS

ERW

ELECTRIC RESISTANT WELDED

EFW

ELECTRIC FUSION WELDED

SMLS

SEAMLESS

LEG PE

PLAIN ENDS

BE

END

BEVELLED ENDS

TE

THREADED ENDS

SO

BW

SLIP-ON

WN

WELDING NECK

LJ

LAP JOINT

RF

FLANGED RAISED FACE

FF

FLANGED FLAT FACE

SCH

SCHEDULE

GALV

GALVANISED

IBR

INDIAN BOILER REGULATION

EPDM

ETHYLENE PROPYLENE DIENE MONOMER

U-PVC

UNPLASTICISED POLYVINYLCHLORIDE

C-PVC

CHLORINATED POLYVINYLCHLORIDE

HDPE

HIGH DESNSITY POLYETHYLENE

NPT

AMERICAN STD. PIPE THREAD (NATIONAL PIPE TAPER)

Gr

GRADE

TOE

THREADED ONE END

TBE

THREADED BOTH END

PSE

PLAIN SMALL END

BLE

BEVELLED LARGE END

THK

THICKNESS

371

NOTES:

1. SPECIFIC REQUIREMENTS GIVEN IN PIPING DRAWINGS OR IN ISOMETRICS SUPERSEDES REQUIREMENTS GIVEN HERE. 2. USE PTFE TAPE FOR THREADED JOINTS FOR TEMPERATURE  200 0C

PRIOR TO WELDING OF GALVANISED PIPING, GALVANISING SHALL BE LOCALLY REMOVED FOR A LENGTH OF 50 mm FROM EACH END. EXTERNAL SURFACE SHALL BE COATED WITH ZINC-RICH PAINT AFTER COMPLETION OF WELDING OPERATION.

374

BRANCH CONNECTION CHART SIZE

BRANCH

inch / mm RUN

15

20

25

32

40

50

65

80

100

15

T

20

RT

T

25

RT

RT

T

32

RT

RT

RT

T

40

RT

RT

RT

RT

T

50

H

H

H

H

H

S

65

H

H

H

H

H

S

S

80

H

H

H

H

H

S

S

S

100

H

H

H

H

H

S

S

S

S

150

H

H

H

H

H

S

S

S

S

150

S

375

LEGEND : T

- EQUAL TEE

RT - REDUCING TEE

H

- HALF COUPLING

TL -THREADOLET

SL - SOCKOLET S

- STUB –IN

WL - WELDOLET N - NIPOLET

SR - STUB-IN WITH R-PAD

376

6.12 SPECIFICATION FOR AIR COMPRESSORS 6.12.1 SCOPE This specification covers the general design, materials, construction features, manufacture, shop inspection and testing at manufacturer‟s works, delivery at site, handling at site, erection, testing, commissioning, performance testing and handing over of Air / Gas Compressors and Accessories. 6.12.2 CODES AND STANDARDS The design, materials, construction, manufacture, inspection, testing and performance of the air/ gas compressors and accessories shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The equipment shall also conform to the latest applicable Indian or equivalent standards. Other international standards are also acceptable, if these are established to be equal or superior to the listed standards. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility. The following are some of the important codes and standards relevant to this specification. a) API 617 Centrifugal Compressors for Petroleum, Chemical, and Gas Service Industry Services b) API 618 Reciprocating Compressors for Petroleum, Chemical, and Gas Industry Services

Plants with Operating Pressures up to 10 bars j) IS 7938 Air Receivers for Compressed Air Installation IS 11780 Code for Selection and Testing of Rotary Screw Air Compressors (Oil Flooded) k) IS 13124 Reciprocating Gas Compressors - Technical Supply Conditions 6.12.3 DESIGN AND CONSTRUCTION FEATURES The compressor shall be of reciprocating or centrifugal or screw type as specified in data sheet A. 6.12.4 RECIPROCATING COMPRESSORS a) Frame The frame shall be a single casting and robust in construction. It shall be provided with sufficiently large and easily removable inspection doors so that the bearings and other parts are readily accessible for checking and adjustments. Inspection doors shall be dust-proof and oil-tight.

b) Cylinder The cylinder shall be made of cast iron or stainless steel or as specified in data sheet A. The cylinder heads and barrels shall be provided with cooling water jackets. The design of jackets shall be such that low air discharge temperature and minimum carbon formation are ensured. The water jackets shall be so constructed that the flow of water is uniform throughout the cooling surface and no stagnant water pockets are formed. The walls of the cylinder shall have sufficient thickness suitable for maximum working pressure and temperature and shall be suitable for reboring. It shall be provided with liberally sized valve openings and streamlined passages. The internal surface of the cylinder shall be highly polished to reduce wear of the piston rings.

378

c) Piston and Piston Rod

The piston shall be of such a design and construction that the piston rings exert equal pressure at all points of the cylinder bore. The piston rod shall be designed to take up the full thrust acting on the piston. The piston rings for non- lubricated type compressor shall be of self lubricating type. Piston speed shall be maximum 300 M/Min for large capacity compressors and 350 M/Min for small capacity compressors.

d) Cross Head

The cross head shall be of solid box type with the faces ground to work closely with the groove of the guides. The cross head pin shall be case hardened and ground.

e) Connecting Rod and Crank Shaft The connecting rod shall be of I cross-section providing adequate strength and rigidity. The crank shaft shall be adequately designed so as to ensure smooth running, without vibrations. It shall be accurately finished to size and shall have sufficient length so as to be fitted to main bearing and flywheel.

f) Flywheel The flywheel shall be designed such that it is well balanced and is of sufficient weight to give an even turning moment. The wheel shall be of robust construction. The spokes shall have oval cross-section and the boss shall have split construction such that the wheel runs true with the shaft. The flywheel shall be suitable for type of power transmission i.e. flat belt, Vbelt, direct coupling etc. between the driver and compressor. g) Main Bearings The main bearings shall be of robust construction assuring long bearing life and shall have sufficiently large diameter and adequate length. The bearing at the crank pin end of connecting rod shall be fitted with bronze lined with best quality white metal. The bearing at the cross head end shall be fitted with a bushing made of bronze. The bearings shall be made in halves and shall have forced feed lubrication. 379

h) Valves The valves shall have straight and uniform lift and maximum effective area so as to ensure low air velocity and minimum valve clearance. The valve plate discs shall be heat treated, tempered and ground and the valve seat shall be case hardened. The valve springs shall be capable of effecting quick opening and closing and shall also provide the required cushioning effect. The valve design shall be such that the valve can be easily removed for checking and maintenance. i) Lubrication (i)

Frame Lubrication

Frame lubrication for small compressors with motor rating upto 55 kW shall be of splash type. The pressurised i.e. forced feed system shall be used for compressors with higher motor rating. In case of force feed lubrication, the oil pump shall be either driven by crank shaft of the compressor or shall be separately driven. The pump shall draw the oil from the adequately sized oil well (ii)

Cylinder Lubrication

For lubricated type of compressors, multi plunger pump or metering pump shall be used for cylinder lubrication. In case of non-lubricated type air compressors, a wiper ring shall be provided such that the crank case oil is not carried to the cylinder along with the piston rod.

6.12.5 SCREW COMPRESSORS a) Casing Casing shall be of barrel type made of cast iron or fabricated steel for moderate pressure applications, cast steel or stainless steel for high pressure applications or as specified in data sheet A. For water injected applications the casing shall be of stainless steel or as specified in data sheet A. Casing shall have built-in air passages either as cast or machined.

b)

Rotors

Rotors shall be of asymmetric profile. The material of construction of rotors shall be as specified in data sheet A. The rotors shall be dynamically balanced before and after mounting 380

Gear pair shall be used to step up speed of the compressor. Helical gear hardened to minimum 55 RC shall be used. Gear shall be shrink fit on drive shaft and shall mesh with pinion mounted on extended portion of male rotor. Gears shall be designed as per AGMA standards.

d)

Bearings

The rotors shall be carried in heavy duty ball and roller bearings to take radial and axial loads or journal bearings with thin babbitt metal lining.

e)

Air- Oil Separator

In case of lubricated screw compressors, high efficiency air-oil separation system shall be provided to ensure removal of oil. 6.12.6 ACCESSORIES Accessories such as intake filter, silencer, inter-coolers, after -coolers, oil-coolers, receivers, control cabinet etc. shall be supplied to make the system complete in all respects.

6.12.7 INTAKE FILTER The intake filter shall be generally as per IS 6206. The type of intake filter shall be as specified in data sheet A. The filter shall be designed to retain particles of one (1) micron and above with ninety-seven (97) percent efficiency. In case of cloth filter, the filter element may be of nylon, polypropylene or woollen cloth attached to the wire netting . 6.12.8 INTER-COOLERS For multi stage compressors, inter-coolers shall be provided. These shall be of shell and tube type, with removable tube bundles. The tubes shall have sufficient thickness to withstand the operating pressure and shall be carefully expanded into the tube sheets. Capacity of intercoolers shall be twenty (20) percent more than the compressor capacity or as specified in data sheet A. Design pressure shall be twenty-five (25) percent more than the working pressure or 381

as specified in data sheet A. The material of construction and design shall be as specified in data sheet A.

6.12.9 AFTER-COOLERS AND OIL-COOLERS The construction features, design etc. shall be as per inter-coolers described above. Capacity of after-coolers and oil-coolers shall be twenty (20) percent more than the compressor capacity or as specified in data sheet A. Design pressure shall be twenty-five (25) percent more than the working pressure or as specified in data sheet A.

6.12.10

RECEIVERS Receivers shall generally conform to IS 7938. Receivers shall be provided with two (2) suitably sized safety valves to relieve the full compressor discharge capacity individually and shall be set at a pressure 1.25 times the operating pressure. The material of construction and design shall be as specified in data sheet A.

CAPACITY CONTROL Capacity control shall be achieved either by speed variation or at constant speed as specified in data sheet A. In case where capacity control is to be achieved at constant speed, following methods are generally available. Data sheet A shall be referred for method to be actually employed.

(a)

Automatic start-stop of the compressor 382

(b)

Automatic load-unload of the compressor

(c)

Throttling of suction valve

(d)

By-passing air or gas from delivery to suction inlet

(e)

Increasing clearance volume by a clearance pocket

(f)

Variable filling using a by-pass valve.

(g)

Movable inlet guide vanes.

6.12.13

DUAL TYPE CONTROL

Capacity control by start-stop and load-unload of compressors is also known as „dual type control‟, and same is described below. The dual type control system shall permit operation of each compressor in either of the following two regulations :

(a)

Continuous Run-Load-Unload Regulation.

(b)

Automatic Start-Stop Regulation.

Under continuous Run-Load-Unload Regulation, the drive motor shall run continuously while the compressor shall be loaded at pre-set (adjustable) cut-in pressure as the receiver pressure falls and unloaded at a higher pre-set (adjustable) cut-out pressure, as the receiver pressure rises. With automatic Start-Stop Regulation, the drive motor shall automatically start at pre-set (adjustable) cut-in pressure as the receiver pressure falls and automatically stop at a pre-set (adjustable) higher cut-out pressure as the receiver pressure rises.

With either system, the compressor shall always be unloaded when the drive motor starts. The unloaders shall keep the compressor unloaded till the drive motor comes to full speed.

Compressor shall be provided with one selector switch having three positions marked AUTO-OFF-ON for the following functions : (a)

OFF

-Stops the motor.

383

(b)

AUTO -Keeps

the

compressor(s)

in

load

/

unload

mode

as

selected by master selector switch. Starts the motor of the compressor in strart-stop regulation as selected by master selector switch. (c)

ON

-For manual start up by push buttons with load /unload regulation.

a) Pressure switches shall be provided to monitor receiver pressure of compressor, one for loadunload control and the other for start-stop control considering two (2) steps regulation for load-unload mode. In case number of steps are more as indicated in data sheet A, number of pressure switches provided shall be sufficient to meet the requirement. b) Pressure switches with alarm initiating contacts shall be provided for the receiver c) high and low pressures. d) The dual control units shall be complete with pressure switches, solenoid valves, control air tubing, air filter (if required) and other accessories as required for the afore-mentioned operations. e) For centrifugal compressors anti-surge control shall also be provided to protect compressor from surging. f) One potential free contact shall be made available for each compressor for remote alarm under trip condition and a common contact for compressor auto start. g) Green and red lamps shall be provided to indicate motor running and stop conditions respectively. h) Motors shall be provided with motor winding over-heat sensors and bearing temperature sensors for alarm indication and to trip the motor. i) For compressors driven with turbine, the required turbine control and instrumentation shall be provided. j) For air / gas compressors, depending on the hazardous area classification, motors and instrument enclosures shall be explosion-proof certified for the specific area.

384

6.12.14 NOISE AND VIBRATIONS a) Noise level produced by any rotating equipment individually or collectively shall not exceed 85 dB(A) measured at a distance of 1.5 metres from the source in any direction. b) The overall vibration level shall be as per zones A and B of ISO 10816-1. Vibration dampening pads if required, shall be provided. 6.12.15

PERFORMANCE GUARANTEES Performance parameters to be guaranteed by the CONTRACTOR and tolerances permitted

CONTRACTOR TO CONFIRM. THE SAME SHALL BE CONSIDERED IN AIR DRIER DESIGN. COMPRESSOR SHALL BE PROVIDED WITH BOTH ON/OFF REGULATION AND LOAD / UNLOAD REGULATION. A TOGGLE SWITCH SHALL BE PROVIDED TO SELECT THE MODE OF REGULATION. HOWEVER THE MOTOR SHALL BE SUITABLE FOR CONTINUOUS OPERATION DUTY.

testing, packing, forwarding, transportation and delivery at site of welded unfired pressure vessels. 6.13.2 CODES AND STANDARDS a) The design, materials, fabrication, inspection, testing and performance of welded unfired pressure vessels shall comply with all currently applicable design codes and standards, statutes, regulations and safety codes in the locality where the equipment is to be installed. The equipment shall also conform to the latest applicable Indian or equivalent standards. Other international standards are also acceptable, if these are established to be equal, or superior to the listed standards. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility. b) If statutory approvals are specified in data sheet A, the VENDOR shall be responsible for obtaining all approvals on design, materials, stage-wise inspection, final inspection and testing of the vessel. 6.13.3 MATERIALS 6.13.3.1 All materials used in the fabrication of pressure vessels shall be as specified in the data sheets. Equivalent materials are acceptable only when approved by the EMPLOYER in writing. 6.13.3.2 All plates shall be ultrasonically tested as follows : (a) For nominal thickness 20 mm and higher when used for fabrication of dished ends (b)

For nominal thickness 40 mm and higher when used for fabrication of shells

(c)

For nominal thickness 50 mm and higher when used for blind flanges

(d)

All thicknesses, when used for body flanges

6.13.3.3 The VENDOR shall ensure that code mandatory requirements of impact testing are met in accordance with the minimum design temperatures specified in the data sheets. 6.13.3.4 Any non-pressure parts such as cleats, pads at support lugs or legs, wear plates at saddles and pads at pipe supports etc., welded directly on to the pressure parts, shall be of the same material as the pressure parts. 6.13.3.5 Reinforcement pads at nozzles and other load bearing locations shall be of the same material and nominal thickness as the pressure part. 6.13.3.6 Material for skirt in case of alloy steel vessels and columns shall be the same as that of pressure part at least for a minimum length of 500 mm from bottom tan-line. 6.13.4 ALLOY STEEL PROTECTIVE LINING AND CLADDING 6.13.4.1 Lining is defined as loose strip lining and bush lining. Cladding may be by weld deposit overlay or explosion bonding or roll bonding. 6.13.4.2 Clad plate or lining shall conform to the following requirements : 390

(a) Clad plate thickness shall be minimum 3 mm, unless specified otherwise. (b) Clad plate made either by the explosion bonding process or reduction roll bonding process is acceptable. (c) Clad plate shall meet the ASME code requirements of SA263, SA264, SA265 including bond test or AD-Merkblatter W-8.The shear bond test shall be executed as per SA264, Figure 1.Ultrasonic inspection shall be carried out in accordance with SA 578, acceptance level S-6. (d) For the purpose of ensuring that cladding thickness of reduction roll-bonded clad plates is not less than 3 mm, each plate shall be inspected at the mill using a "coating gauge". Plates shall be scanned on at least three edges and one across the width of the plate. Thickness shall be plotted at points not more than 600 mm apart. The VENDOR shall furnish a mill certificate, showing an outline of the plate and the points at which readings were taken together with the results. (e) Instead of lining, weld deposit overlay may also be considered. (f) At weld deposit overlay

or clad-restoring welds, at least the same chemical

composition shall be present at 3 mm depth, to be analysed by the welding procedure qualification in advance. (g) Weld deposit overlay and clad-restoring welds shall be dye penetrant tested and crack-free. (h) Weld deposit overlay and clad-restoring welds as a minimum, shall be qualified as per ASME Section IX. 6.13.4.3

6.13.4.4 6.13.4.5

Alloy steel lining shall not be used when cladding is specified. Alloy steel lining, when specified, shall be so designed that the distance between attachments does not exceed 150 mm. The minimum required thickness of pressure parts shall exclude cladding or lining. Cladding or lining requirements discussed in this specification are using low and high alloy steels only. For cladding or lining using non-ferrous and other materials, when specified, the VENDOR shall furnish on his drawings all details, including Welding Procedure Specification (WPS), for review and approval.

6.13.5 MINIMUM THICKNESS 6.13.5.1 The thicknesses of the pressure parts as shown in the data sheets or drawings are the minimum acceptable thicknesses after manufacture, even though the code may permit a lesser thickness. The minimum acceptable thickness includes specified corrosion allowance. 391

6.13.5.2 The VENDOR shall be responsible for proper selection of plate thickness considering the fabrication and forming allowances, mill under-tolerances etc., to meet the minimum thickness requirements as specified. 6.13.6 SHELLS Shell courses shall be of the largest possible dimensions to minimise the number of weld seams. 6.13.7 HEADS AND REDUCING SECTIONS a)

Reducing sections or conical bottoms shall have a knuckle radius of r = 0.06D, unless specified otherwise. However, knuckle radius shall not be less than 50 mm.

c)

Dished ends shall be seamless or 100% radiographed when made from more than one piece.

6.13.8 AGITATOR ASSEMBLY a) Agitator assembly shall be complete with drive motor, mechanical seal with seal housing, bearings, gear box, agitator shaft with impellers, foot-step bearing with support, rigid coupling between agitator shaft and gear box output shaft with spool piece, flexible couplings between gear box and drive motor, suitable base plate and supporting structure for agitator drive arrangement and necessary fasteners etc. so as to make it complete in all respects. b) Drive motor and gear box shall be mounted on a common base frame and duly coupled and aligned through flexible couplings. c) Agitator shaft and gear box output shaft shall be coupled through a rigid coupling with split ring locking arrangement in order to ensure that agitator shaft does not fall into the vessel during operation. d) Agitator, shaft and impeller assembly shall be statically and dynamically balanced. e) The VENDOR shall obtain necessary approvals from the seal manufacturer regarding arrangement of assembly and application of API cooling plan etc. for the mechanical seal. f)

The gear box shall be rated for heavy duty agitator service, continuously working for 24 hours a day and shall be suitable to withstand static and dynamic loads and bending moment on the gear box due to agitator shaft.

g) Drive motor and gear box unit shall be provided with a suitable lifting eye hook. h) There shall be no oil spillage from gear box on to the vessel. 392

6.13.9 NOZZLES AND MANHOLES a) Nozzles fabricated from plates are acceptable for sizes larger than 250 mm NB in case of carbon and low alloy steels and 150 mm NB in case of high alloy steels. However, this is to be done with prior approval and subject to all welds being 100% radiographed. b) All nozzle sizes and quantities indicated in the data sheets are tentative and for bid purpose only. Final sizes and quantities are subject to confirmation during review of drawings. The CONTRACTOR shall include and confirm in his BID, that changes, to the extent of one size lower or higher for each nozzle and quantities plus or minus one number for each size, are acceptable at no extra cost to the EMPLOYER. c)

All nozzles with butt-welding end connections shall have edge preparation as per ANSI B16.25 suitable for connected piping inside diameter. Such nozzles shall have 100 mm extra stub length with pipe caps for hydrotest purpose.

d) All nozzles of sizes 40 mm NB and below shall be gusseted as per the companion specification e)

All openings in pressure parts shall be compensated for the area of opening as per code. Minimum width of pad shall be 50 mm.

f)

All load bearing areas in pressure parts shall be verified for buckling

and

local

stresses.

Adequate reinforcement shall be provided. g) Nozzle and manhole necks shall be flush with the inside surface of vessel, unless specified otherwise. Inside edges of manholes shall be smooth and rounded-off with a radius of 3 mm. 6.13.10 FLANGES a) Unless specified otherwise, all nozzles shall be provided with rated flanges only, from consideration of interchangeability, as per the dimensional standards indicated in the data sheets. b) Bolt holes shall straddle the main vessel axes, unless specified otherwise. c)

All flanges on nozzles shall be of forged construction with integral hubs. Plate or plate type forged flanges are not acceptable in place of forged flanges with integral hubs.

g) When companion flanges are of welding neck type, the same shall be to suit bore of connected pipe.However,this information shall be provided by the EMPLOYER, during review of drawings. h) Blind flanges and covers intended for inspection or access openings shall be provided with adequate arrangement to facilitate opening and closing without undue effort. i)

Unless specified otherwise, seating surfaces for non-metallic gaskets shall have stock or serrated finish. For other types of gaskets, the type of finish shall be furnished by the VENDOR on the drawings for review and approval.

j)

When flanges specified are of tongue and groove or male and female type, groove or female face shall be on the nozzle flanges and tongue or male face on the companion flanges.

6.13.11 SUPPORTS a) All skirt supports shall have at least one access opening and adequate vent holes at the top of skirt. b) Skirt shall be provided with adequate holding and climbing rungs inside, above and below the skirt opening. Details shall be furnished by the VENDOR on the drawings for review and approval. 6.13.12 MISCELLANEOUS a) The sizing of vessel internals shall be such that all removable parts can be removed through manholes. b) Wherever applicable and unless specified otherwise in data sheets all support rings, bolting bar for internals such as trays, tower packings, downcomers etc. shall be in the scope of the VENDOR. c)

Internal baffles, tray support beams of other internals spanning a chord or diameter of the vessel shall be provided with a means for allowing differential expansion between the part and the vessel shell. 394

d) Unless specified otherwise, baffles or weir plates shall not be welded directly to the shell or dished end of the vessel. These shall be bolted to the support attachments which are welded to the shell or dished end. e)

The CONTRACTOR shall include two (2) numbers stainless steel name plates in his scope. This requirement is exclusive of manufacturer's name plate. The details on name plate shall be furnished during review of drawings.

f)

Lifting lugs shall be provided for all vessels. Details are subject to review and approval.

g) Earthing cleats as per companion specification shall be provided at the approved locations. h) All pads at nozzles, supports etc. shall be provided with a tell-tale hole at the bottom-most location, which shall be tested with air at 1.0 kg/cm²(g) and checked with soap solution for leakage. Such tall-tale holes shall be plugged after satisfactory testing. i)

For insulated or fire proofed vessels, insulation or fire proofing supports as per enclosed companion specification shall be provided by the VENDOR.

j)

Wherever platforms and ladders are specified in the data sheets, necessary supports shall be provided by the VENDOR as per details which shall be made available during review of drawings.

k) Where materials are “free issue” as indicated in the enquiry specification or data sheet, the CONTRACTOR shall furnish along with the technical BID, a firm Bill of Materials (BOM) of all “free issue” items and also indicate cutting and wastage allowances both accountable and unaccountable. 6.13.13 ANCHOR BOLTS Anchor bolts are not included in the scope of supply of the VENDOR, unless specified otherwise in the data sheets. 6.13.14 FABRICATION a) All welders, WPS and Procedure Qualification Records (PQR) shall meet the b) requirements of the specified code irrespective of pressure service or non-pressure service. c)

Before welding, edges shall be checked in order to ascertain the absence

Butt-welds shall have full penetration. Single sided welds shall be chipped back to sound metal and rewelded from the other side. Wherever chipping is not possible, root run shall be by TIG. Backing strip shall not be used without prior approval.

Nozzle and reinforcement pads, where applicable, shall be set-in type and attached to the vessel by full penetration welds.

k) Skirt to vessel heads joints shall have continuous flat-faced weld matching with outer diameter of the vessel. The width of the weld shall be equal to skirt thickness and height of weld shall be twice the width. l)

All welds shall be deburred, free from under cuts, overlap ridges and valleys.

m) No welding shall be carried out after stress relieving and/or postweld heat treatment. All flange faces shall be suitably protected against oxidation during heat treatment. 6.13.15 FIELD ERECTION a) Where size or shape of vessel makes it impossible to ship it in one piece for erection by others, the VENDOR shall ship largest shop fabricated sections suitable for shipment and ease of handling for field erection and assembly. Fabrication and erection shall be completed at the site by the VENDOR. b) All pieces shall be shop fit-up into sections and each sections shall be fit to adjacent section and all pieces shall be match marked. c)

The width of permissible gap during fit-up shall be in accordance with approved drawings and welding procedures and shall generally be 3 mm maximum with a tolerance of plus 0.8 mm to minus 0.0 mm.

d) Flame cut edges shall be ground by the VENDOR as required to remove slag, detrimental discoloration and non-uniformity of edges.

396

e)

All radiographic requirements for welds completed in shop shall be made by the VENDOR before the parts of section leave the shop.

6.13.16

PAINTING All carbon steel exteriors shall be descaled, edges deburred and wire brushed. Subsequently, all such surfaces shall be painted with two coats of red oxide primer.

6.13.17

ESSENTIAL AND RECOMMENDED SPARES The CONTRACTOR shall include following essential spares in his scope of supply : a) Two (2) gaskets as spares for each nozzle b) Three (3) gaskets as spares for body flanges c) 10% spare fasteners of each size and length. However, the minimum quantity shall be four (4) for each size and length.

2 - WITNESSING BY TCE MAY BE 100 % OR ON RANDOM SAMPLES. 3 - THIS DOCUMENT SHALL BE READ IN CONJUNCTION WITH INSPECTION REQUIREMENTS MENTIONED IN RELEVANT TECHNICAL SPECIFICATIONS. 4 - THE PRESSURE GAUGES AND INSTRUMENTS FOR MEASURING CRITICAL PARAMETERS SHALL HAVE VALID CALIBRATION CERTIFICATE TRACEABLE TO NATIONAL LABORATORY.

4 - THE PRESSURE GAUGES AND INSTRUMENTS FOR MEASURING CRITICAL PARAMETERS SHALL HAVE VALID CALIBRATION CERTIFICATE TRACEABLE TO NATIONAL LABORATORY.

401

1 OF 1

NOTES:

SHEET

LEGEND:

402

6.14 SPECIFICATION FOR LOW VOLTAGE INDUCTION MOTORS 6.14.1 SCOPE The specification covers the design, material, constructional features, manufacture, inspection and testing at the VENDOR'S/his SUB-VENDOR'S works, delivery to site and performance testing of Low Voltage induction motors rated up to 1000V. 6.14.2 CODES AND STANDARDS The design, material, construction, manufacture, inspection, testing and performance of induction motors shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. The equipment shall also conform to the applicable standards specified in data sheet A1 latest revision as on the date of offer. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility. In case of conflict between the standards and this specification, this specification shall govern. 6.14.3 DRIVEN EQUIPMENT a) When this specification forms part of the driven equipment specification, information

not given in the Data Sheet-A will be governed by the driven

equipment

specification.

b) Motors shall be capable of satisfactory operation for the application and duty as specified in the motor Data Sheet-A and as specified for the driven equipment.

6.14.4 PERFORMANCE AND CHARACTERISTICS i) Motors shall be capable of giving rated output without reduction in the expected life span when

operated continuously

under either

of the following

supply

conditions as specified in Data Sheet-A1. Supply Condition I

II

a)

Variation of supply voltage from rated voltage

+/- 6%

+/-10%

b)

Variation in supply frequency from rated frequency

+/-3%

+/- 5%

c)

Combined voltage and frequency variation

+/- 6%

+/-10%

ii)

Motors shall be suitable for the method of starting specified in the Data Sheet-A.

iii) The minimum permissible voltage shall be 85% of the rated voltage during motor

starting 403

iv) Motors shall be capable of starting and accelerating the load with the applicable

method of starting, without winding temperatures reaching injurious levels, when the supply voltage is in the range of 85% of the rated motor voltage to maximum permissible voltage specified in Data Sheet-A1. v)

The locked rotor current of the motor shall not exceed 600% of full load current (subject to tolerances as per the applicable standard) unless otherwise specified.

vi) Motors shall be capable of developing the rated full load torque even if the supply

voltage drops to 70% of the rated voltage. The pull out torque of the motor shall be atleast 205% of full load torque. vii) Motors when started with the driven equipment coupled shall be capable of

withstanding at least two successive starts from cold conditions & one start from hot condition without injurious heating of windings. The motors shall also be suitable for three equally spread starts per hour under the above referred supply conditions. viii) Motors shall be of Energy Efficient type if specified in Data sheet-A1. Category of

Energy efficiency shall be as mentioned in data sheet-A1 6.14.5 INSULATION i) The insulation shall be given tropical and fungicidal treatment for successful operation of the motor in hot, humid and tropical climate. ii)

Insulation of VFD controlled Motors shall be designed to withstand a dv/dt of 0.1 micro sec rise from 10 % to 90 % of steady voltage and a maximum peak of 1600 volts as per NEMA standard MG1 Part 31.40.4.2

6.14.6 TEMPERATURE RISE i) The temperature rises shall not exceed the values given in IS 12802. Under extremes of supply condition (clause 4.1 above), the temperature rise shall not exceed the value indicated in IS by 10oC. ii)

For motors specified for outdoor installation heating due to direct exposure to solar radiation shall be considered.

6.14.7 CONSTRUCTIONAL FEATURES i) All windings shall be of Copper. ii)

Motors weighing more than 25 kg. shall be provided with eyebolts, lugs or other means to facilitate safe lifting.

PAINT AND FINISH All motor parts exposed directly to atmosphere shall be finished and painted to produce a neat and durable surface which would prevent rusting and corrosion. The equipment shall be thoroughly degreased, all rust, sharp edges and scale removed and treated with one coat of primer and finished with two coats of grey enamel paint.

ACCESSORIES i) Two independent earthing points shall be provided on opposite sides of the motor, for bolted connection of the EMPLOYER'S earthing conductors as specified in data sheetA. These earthing points shall be in addition to earthing stud provided in the terminal box. ii) Except when otherwise specified, the motors shall be provided with a bare shaft

extension having a key slot and a key at the driving end. 6.14.13

TESTS i) All Motors shall be subjected to all the routine tests as per applicable standard in the presence of the EMPLOYER‟s representative. ii) Type tests Certificates shall be furnished for motors below 37kW. If type tests have

not been carried out on similar Motors, or if the type test reports submitted are not found in order, then VENDOR shall carry out these tests without any extra cost to the Employer. iii) Following Type tests shall be performed in the presence of the EMPLOYER‟s

representative for motor rating of 37kW and above, one of each rating: 406

7.1 INTRODUCTION – ELECTRICAL 7.1.1 Followings CPWD Specification for Electrical shall take precedence over provisions of relevant I.S. Codes.  CPWD specification for electrical works part I internal 2013  CPWD general specifications for electrical works - part ii (external) 1994  CPWD general specifications for electrical works part-iv substation 2013 7.1.2 All Electrical works shall be carried out in accordance with the provisions of National Electrical Code 2011 and Central Electricity Authority 2010. 7.1.3 Refer following Detailed Technical specifications for items which are not covered in above mentioned CPWD Specifications. This specification is to be read along with SLDs and BOQs. In case of any conflict in specification, BOQ spec/ description will be followed.

7.2 HIGH VOLTAGE METAL ENCLOSED SWITCHGEAR 7.2.1 Scope Supply, Manufacturing , installation, testing commissioning of integrated cubicle type metal clad, form 3 a, floor mounted and draw out type free standing, front operated indoor type 33 kV switchgear as per following specifications : 7.2.1.1 General The switchgear enclosure shall conform to degree of protection IP -52. The switchgear shall be made from MS sheet steel 2 mm thick (CRGO) and shall be folded and braced as necessary to provide a rigid support for all components. The switchgear assembly shall form a continuous dead front line up of free standing vertical cubicles. Each cubicle shall have a lockable front hinged door and a removable bolted back cover. All covers and doors shall be provided with neoprene gaskets. Suitable arrangement for lifting of each cubicle shall be provided. Design and construction of the switchgear shall be such as to permit extension at either end. Vacuum Circuit breaker shall be provided with surge arresting device for protection against lightning and switching over voltage. Two separate and distinct connections to earth shall be provided for each surge arrestor. Suitable earthing trolley/ truck shall be provided separately for each substation. 7.2.1.2 Breaker Compartment Vacuum Circuit Breaker shall be mounted in draw out truck with front plate which covers the cubicle when the breaker is in service position. Draw out mechanism shall be horizontal type. This front plate shall be provided with view glass to facilitate observation of mechanical ON/OFF indication of Circuit breaker, Spring charged / discharged indication and operation counter. Necessary orifice shall be provided for manual charging of the springs. ON/OFF push button for opening and closing of the 419

circuit breaker shall also be provided. The draw out truck shall have two positions for the circuit breaker VIZ isolated / Test & Service. 7.2.1.3 Bus Bar Compartment Bus bars of rectangular cross section of copper conductor supported by cast epoxy insulator to withstand full short circuit currents upto 18kA for 33 kV system shall be provided at the rear. Bus bar chamber shall be provided with inter panel barriers with epoxy cast seal off bushings. 7.2.1.4 CT and Cable Compartments At the rear of the panel sufficient space shall be available to accommodate three numbers epoxy CT‟s of double core and two numbers three core cable termination. The cable entry shall be from the top / bottom. 7.2.1.5 Separate Compartments Circuit breakers, instrument transformer, bus bars, cable etc shall be housed in a district different compartments as required for form 3 a, compartmentalization. All relays, switches, lamps, etc. comprising the control, indication and protective devices shall be housed in a separate compartment on the front of the cubicle. 7.2.1.6 Technical Particulars of Vacuum Circuit Breaker S.NO.

DESCRIPTION

33 kV

A

Rated Current

630 A

B

Rated Voltage

36 kV

C

Rated Frequency

50Hz

D

Rated Short Circuit breaking Current

18 kA

E

Rated short circuit making current (kAP)

66 kA

F

Insulation level (kV rms/kVP)

70 kV / 170 kV

7.2.1.7 Isolating Contacts The breaker isolating contacts shall consist of two parallel flat silver plated copper bars with ball point contacts to give a vertical tolerance of ±10 mm. 7.2.1.8 Low Voltage Plug and Socket Connector A twenty pin plug and socket connection along with flexible leads shall be provided to connect control instrumentation and interlock circuits on the breaker truck and in the panel. The plug and socket assembly shall be suitably interlocked with the truck positions like service and test/isolated position. 7.2.1.9 Interlocks and Safety Devices The following interlocks shall be provided: a)

The truck cannot be moved from either test to service position or vice versa, when the circuit breaker is „ON‟. 420

b) c) d) e) f) g)

The circuit breaker cannot be switched „ON‟ when the truck is in any position between test and service position. Front part of the truck cannot be removed when the breaker in „ON‟ position. The truck cannot be inserted when the earthing switch is „ON‟. The low voltage plug and socket cannot be disconnected in any position except test/isolated position. The truck cannot be moved inside the panel, when the LT plug and socket is disconnected. Earthing switch cannot be switched „ON‟ when the truck is inside the panel.

7.2.1.10 Safety Devices The following Safety devices shall be provided for the safety of the operating personnel: a)

b) c) d)

Individual explosion vents shall be provided for breaker chamber/bus bar/cable chambers on the top of the panel to let out the gases under pressure generated in case of fault inside the panel. Cubicle with front plate to withstand the pressure for internal arc fault as per PEHLA recommendation. Circuit breaker and sheet metal enclosure shall be fully earthed. Self locking shutters shall be provided which shall close automatically when the truck is withdrawn to „Test position‟ and no separate padlocking of the shutter shall be required.

7.2.1.11 Protective Earthing The earthing connection between the truck and the cubicle shall be by means of sliding contacts so that the truck is earthed in the isolated position when inserted and remains earthed when the truck is pushed further into the connected position or when the truck is being withdrawn until the truck has moved part the isolated position. 7.2.1.12 Current Transformer General Requirements Accommodation shall be provided in the circuit breaker panel, to mount one set of duel ratio CT. Access to the CTS for cleaning, testing or changing shall be from the front, back or top of the panel. Rating Duel ratio CTS of suitable burden (but each not less than 15 VA) shall be preferred with 5 amps secondaries. Instrument Security Factor (ISF) of each CT shall not be more than 5. The CTs shall conform to relevant Indian Standards. The design and construction shall be dry type, epoxy resin cast robust to withstand thermal and dynamic stresses during short circuits. CT terminals shall be shorting type. Current & voltage circuits shall be laid in separate wire ways. Secondary terminals of CTS shall be brought out to a suitable terminal block which will be easily accessible for terminal connections. Test terminal block shall be provided in the front side of the panel for testing purpose. 421

CT‟S shall have 2 Nos. of cores for following application: Core -1 for metering Core -2 for over current & earth fault protection. Class of accuracy for winding Metering class

0.5

Protection class

5P10

7.2.1.13 Potential Transformers The potential transformers shall be confirming to IS 3156/ IEC 60185.The primary windings of the potential transformers shall be insulated and shall be of the cast rest in type. Potential transformer (PT‟S) shall be mounted on a draw out trolley and housed in separate metal compartment and shall have control fuses on the H.V. side and a miniature circuit breaker on the L.V. side of the windings.HT HRC Control fuses shall be confirming to IS – 9385/ IEC –60282.Miniature Circuit breaker shall comply with IS – 8828/ IEC – 60898. Padlocking facilities shall be provided for both service and isolated position. The potential transformer shall be as specified below: Ratio

:

33000 /√3/ 110/ √3/ 110 V 110 V

V A Burdan

:

100 V A for 100/√3 and 110 V winding

Class

:

CL –1 for both the windings.

Basic Insulation level 6.

:

Same as mentioned for VCB in clause -

Over voltage factor

:

1.2 Continuous

Single phase PT‟S shall be used and shall be connected in Star/ Star. 7.2.1.14 Protection and Tripping Arrangement Protection All protection relay shall be numeric type of approved make. The protection and tripping arrangement of circuit breaker shall be Provided as per BOQ & as mentioned below:a) b)

Numeric type instantaneous short circuit protection Device No.50 Range 500 – 2000% shall be provided on all phases. Numeric type back up over current protection for Phase faults Device No.51 Range 50 – 200% shall be provided on all phases.

The control wiring shall be carried out with 1.5/2.5 sq. mm. PVC insulated copper conductor cables. The wiring shall be securely fixed and neatly arranged to enable easy tracing of wires. Identification PVC ferrules shall be fitted to all wire terminals to render easy identification and facilitate checking in accordance with IS 5578 and 11353. 7.2.1.16 Metering Instrument Panel Accessories Metering Digital type Trivector meter of approved make (Smart demand controller) shall be provided on the incomer feeder. Specification of the meter shall be as follows: Accuracy

:

Class 0.5, compliant to revenue class certification.

:

Real time measurement per phase & average V, I, PF, kW, kVAR, kVA

:

Peak demand, sliding window. Protected.

:

V & I unbalance, Phase reversal

:

Time of Use (TOU)

Power Quality Measurement: :

Total Harmonics

Logging & recording for all measurements:

: Alarming functions.

:

Interval or event-based, 32 channel measurement & recording

:

Event logging

:

“Bust” data recording

Min/ Max recording :

Over & under measurement detection by 24 set point

Multiport Communication:

One each of RS 485 and RS 232 ports.

7.2.1.17 Instrument Panels The instrument panel shall be part of the housing. Relays, meters and instruments shall be mounted as per general arrangement drawings to be submitted by the vendors. They shall be of flush mounting type. 7.2.1.18 Instrumentations a) Digital type Voltmeter of class 1.0 accuracy and 96 x 96 mm square in size as per IS-1248 shall be provided at incomer panel, with selector switch. The instrument shall be calibrated for the ranges specified. b) Digital type Ammeter of specified range to class 1.0 accuracy and 144 x 144 sq mm in size as per IS - 1248 shall be provided at both incomer and outgoing panels along with necessary selector switches. c) Digital type frequency meter class of 1.0 accuracy conforming to IS:1248 shall be provided at incomer panel. d) Digital type Power factor meter of class of 1.0 accuracy conforming to IS : 1248 shall be provided at incomer panel. The following minimum indication lamps shall be provided in the front of cubicle. 423

Breaker open / closed / tripped, spring charged, trip circuit healthy and control supply healthy. Lamps shall be clustered LED type and trip circuit supervision scheme shall be of continuous supervision type. After meeting all necessary control and indication requirements 2 nos. NO and 2 nos.. NC auxiliary of the breaker shall be made available for the Employer, wired up to terminal block. Separate MCB‟s shall be provided for lamps, heaters and other instrumentation etc. on each panel. Anti-condensation space heaters suitable for operation on 240 V single phase, 50 Hz A.C. for each cubicle and with thermostat control one incandescent lamp with switch and 3 pin 5 amps plug socket. 7.2.1.19 Inspection and Testing After manufacturing of switchgear panels tests shall be carried out on the equipment as per relevant IS and Electricity Regulations. 7.2.1.20 Quality Assurance Vendor shall submit in substantial detail a quality assurance plan indicating all activities step by step at various manufacturing/fabrication stages to meet the requirement of this specification and various standards/regulations/practices to enable comprehensive assessment of its merits and reliability.

7.3 LOW VOLTAGE SWITCHGEAR 7.3.1 Scope This Section covers the detailed requirements of medium voltage switch Panel for 433V, 3 phase 50 Hz 4 wire system. These shall be branded and/or assembled/fabricated from a factory of repute. All switchgears shall be fully rated at an ambient of 50° C. Type of Panel The medium voltage switch board panel shall comprise of any one of the following types of switchgears or combination thereof as specified. Air Circuit breakers draw out or fixed type, Switch Disconnector Fuse Units fixed type, MCCBs of suitable Ics ratings. MCCBs shall invariably be Current Limiting type. Features like Double Break, Positive Isolation functions shall be preferred. The Panel shall be indoor type having incoming sectionalization and outgoing switchgears as specified. The design shall be cubical type. The degree of enclosure protection shall be IP 42 as per IS: 13947 (Part-I). 7.3.2 LT Panel 7.3.2.1 General Construction a) The switchboard shall be floor mounted free standing totally enclosed and extensible type of uniform height not more than 2400mm. The switch board shall be dust & vermin proof and shall be suitable for the climate conditions as specified. The design shall include all provisions for safety of operation and maintenance personnel. The general construction shall conform to IS: 8623/1993 for factory assembled switch board.

424

b) LT Panels shall be provided with a metal sill frame made of structural steel channel section properly drilled for mounting the Switchgear along with necessary mounting hardware. Hardware shall be zinc plated and passivated, Provided with cable entry facilities at top/bottom as per layout requirement with 3mm thick removable gland plates on breaker panels and 2 mm thick removable gland plates on other panels with necessary cable glands. For 1-core cables, these plates shall be non-magnetic. c) Switchgear shall be provided with gaskets all round the perimeter of adjacent panels, panel and base frame, removable covers and doors, d) Provided with busbars running at the top, as required, all along the length of the switchgear in a separate sheet steel enclosure. 7.3.2.2 Cubical Type Panels Cubical type panels shall be fabricated out of sheet steel not less than 2.0 mm thick. Wherever necessary, such sheet steel members shall be stiffened by angle iron frame work. General construction shall employ the principle of compartmentalization and segregation for each circuit. Unless otherwise approved, incomer and bus section panels or sections shall be separate and independent and shall not be mixed with sections required for feeders. Each section of the rear accessible type panel shall have hinged access doors at the rear. Overall height of the panel shall not exceed 2.4 meters. Operating levers, handle etc. of highest unit shall not be higher than 1.7 meters. Multi-tier mounting of feeder is permissible. The general arrangement for multi tier construction shall be such that the horizontal tiers formed present a pleasing and aesthetic look. The general arrangement shall be approved before fabrication. Cable entries for various feeders shall be either from top or bottom. Through cable alleys located in between two circuit sections ,either in the rear or in the front of the panel. All cable terminations shall be through gland plates. There shall be separate gland plate for each cable entry so that there will not be dislocation of already wired circuits when new feeders are added. Cable entry plates shall therefore be sectionalized. The construction shall include necessary cable supports for clamping the cable in the cable alley or rear cable chamber. Cubicle panels with more than 1000 Amps BUS shall be made of tested structural modular sections. 7.3.2.3 Bus Bar and Connections The bus bars shall be of Copper/Aluminuum of high conductivity electrolytic quality and of adequate section. Current density shall not exceed 130 amps for Copper /sq. cm. The bus bar system may comprise of a system of main horizontal bus bars and ancillary vertical bus bars run in bus bar alleys on either side of which the circuit could be arranged with front access cable entries. In the case of rear access, horizontal bus system shall run suitably either at the top or bottom. All connections to individual circuits from the bus bar shall preferably be solid connections; however flexible connections shall also be permitted as per recommendations of the Panel Manufacturer. All bus bars and connections shall be suitably sleeved / insulated with heat shrinkable PVC with approved manner. The insulation shall be non-inflammable and self-extinguishing and in fast colours to indicate phases. The joints shall be insulated in such a way as to provide for accessibility of contact bolts for maintenance. Joints shall be covered with removable moulded shrouds made out of fibreglass-reinforced polyester. 7.3.2.4 Incomer I Termination 425

Incomer termination shall be suitable for receiving bus trunking /underground cables. Cable terminations shall invariably be through terminal blocks (Polyamide or superior) or brought out solid terminals. 7.3.2.5 Instruments All voltmeters and ammeters shall be flush mounted of size minimum 96 mm conforming to class 1,5 of IS: 1248 for accuracy. All voltmeters shall be protected with MCB. They shall be suitable for semi-flush with only flanges projecting on vertical panels. 7.3.2.6 Indicating Lamps On all the incomers of M.V panels, ON/OFF indicating LED lamps shall be provided and shall be suitable for operation on AC supply. Phase indicating LED lamps shall be associated with necessary ON/OFF toggle switch. 7.3.2.7 Small Wiring All small wiring for Controls, Indication etc, shall be of with suitable FRLS/HFFR (halogen free fire retardant) copper conductor cables. Wiring shall be suitably protected within switch board. Runs of wires shall be neatly bunched, suitably supported and clamped. Means shall be provided for easy identifications of the wires. Where wires are drawn through steel conduits, the works shall conform to CPWD General Specifications for Electrical works (Part I- Internal) - 2005 and IS:732 as the case may be. Identification ferrules shall be used at both ends of the wires. All control wiring meant for external connections are to be brought out of terminal board. 7.3.2.8 Operational Requirements The indoor type LT panel shall conform to the following: The panel shall comprise of incomers, outgoing feeders and bus coupler as specified. The incomer shall be either a double break / contact repulsion MCCB or an Air Circuit Breaker. The bus coupler shall be either a circuit breaker or a double break / contact repulsion MCCB, ACB, switch disconnector fuse unit as specified. The outgoing feeders shall be circuit breakers/MCCBs as specified. Bus bars for phase and neutral shall have a rating as specified in SLD and BOQ. The entire switch panel shall be cubical type 18:8623/1993 for factory assembled switch board.

generally conforming to

The incomer panel shall be suitable for receiving bus trunking or LT cable of size specified either from top or from bottom. All incoming AIRCIRCUIT BREAKER/MCCB shall have suitable adjustable tripping current and the time delay settings. The entire panel shall have a common earth bar of size as specified with two terminals for earth connections. 7.3.2.9 Rating and Requirements Air Circuit Breaker* All Air Circuit Breakers shall be 3/4 pole with minimum 50 KA breaking capacity (35 MVA at 433V) conforming to IS: 13947 (Part-II). Rated current shall be as per capacities specified. The equipment shall be complete with the following: a) Necessary circuit breaker carriage with 3 position (isolate, test, service) draw-out mechanism. 426

j) In case of 4 pole breaker neutral shall be fully rated with adjustable settings from 50% to 100%ofln. k) ACB terminals shall be suitable/suitably brought out for direct aluminum termination as per IS 13947 Part-II. l) Provided with „red‟, „green‟ and „amber‟ indicating lamps to indicate „closed‟ „open‟ and „auto-trip‟ conditions of the circuit breaker when breaker operation is controlled by a control switch. m) All indicating lamps shall be clustered LED type, with in-built short circuit, surge protections etc. Adequate number of contacts shall be provided to have remote annunciation of the breaker feeders: Breaker 'ON' Breaker 'OFF' Breaker 'TRIP' Breaker 'Service' Breaker 'Test' Note: Wherever fixed type circuit breakers are required, it shall be clearly specified. MCCB/ MCB etc: MCCBs : All MCCBs shall be current limiting type with features of load line reversibility and suitable for Horizontal/Vertical mounting without any derating. Beyond 300 Amps capacity MCCBs shall have positive isolation and preferably double break / contact repulsion & double insulation features. The MCCBs shall invariably be used with terminal spreaders. a) The MCCBs shall conform to the latest applicable standards (IS: 13947). b) MCCBs in AC circuits shall be of TP/TPN/FP construction arranged for simultaneous manual closing and opening. Operating mechanism shall be quickmake, quick-break and trip-free type. The ON, OFF and TRIP positions of the MCCB shall be clearly indicated and visible to the operator. Operating handle for operating MCCBs from door of board shall be provided.

427

c) The instantaneous short circuit release shall be so chosen by the CONTRACTOR as to operate at a current in excess of the peak motor inrush current and a range of settings shall be provided for the EMPLOYER „S / ENGINEER‟S selection. d) MCCB terminals shall be shrouded and designed to receive cable lugs for cable sizes relevant to circuit ratings. e) Minimum no. of additional auxiliary contacts (for Employer‟s use) shall be provided. f)

MCCBs shall incorporate time delay devices to ensure that it will tolerate harmless transient overload unless this is well in excess of 25% of its rated value for a sustained period.

MCBs: Miniature circuit breakers for use on motor space heater control circuits shall comply with the requirements of applicable standards, unless otherwise mentioned in Data Sheet. CONTACTORS: Motor starter contactor shall be of the electromagnetic type rated for uninterrupted duty as defined in applicable standards. Main contacts of motor-starter contactors shall be of silver plated copper. Contactors shall be of the double break, non-gravity type. Direct-on-Line Starters/Star Delta Starters : Starters shall be suitable for Class AC 3 utilisation category as specified in applicable standards. 7.3.3 Lightning and Surge Voltage Protection 7.3.3.1 Scope This specification describes the electrical and mechanical requirements for a high energy Transient Voltage Surge Suppressor (TVSS).The specified TVSS/SPD system shall be connected in parallel to the facility‟s electrical all main incoming panels. It shall provide effective high energy surge current diversion, and shall be suitable for application in ANSI/IEEE C62.41 Category A, B and C environments or IEC 616431 Class I, II and III 7.3.3.2 Codes & Standards The specified system shall be designed, manufactured, tested and installed in compliance with the following codes and standards: IEC 61643-1: Surge Protective Devices connected to low voltage power distribution systems. Underwriters Laboratories: (UL 1449, 2nd edition) Standard for Transient Voltage Surge Suppressors. International Standards Organization (ISO) Company certified ISO9001 for manufacturing, design and service and the applicable portions of the American National Standards Institute and Institute of Electrical and Electronic Engineers standards (ANSI/IEEE 1100 ,C62.11, C62.41, C62.45) 7.3.3.3 Electrical Requirements a)

Nominal system operating voltage The single phase TVSS system shall be suitable for installations operating between 220VAC and 240VAC. The three phase TVSS system shall be suitable for installations operating between 380VAC to 415VAC, Star (Y) Configuration: 3 Phase 4 Wire Plus Ground or Delta Configuration: 3 phase 4 wire including Ground. 428

b)

Maximum Continuous Operating Voltage (MCOV): The maximum continuous operating voltage of the complete TVSS, as well as all components in the suppression path shall be greater than 125% of the nominal system operating voltage to ensure the ability of the system to withstand temporary RMS over voltages (swell conditions).

c)

Operation Frequency: The operating frequency range of the system shall be 50 or 60 Hz.

7.3.3.5 Short-circuit Withstand Capability: The TVSS shall be able to carry the power short circuit current until it is interrupted by external over-current disconnect or by the backup over current protection. The minimum Short Circuit Withstand of the TVSS shall be according to the table below: Class

Minimum Capability

Class C

200KA

Class B

35 to 65KA

Class A

14KA

Short

Circuit

Withstand

7.3.3.6 Over current Protection (fusing) All components, including suppression, filtering, and monitoring components, shall be individually fused at the component level with the fuses rated so as not to impede maximum specified surge current capacity. The fuse shall be capable of opening in less than one millisecond and clear both high and low impedance faults. 7.3.3.7 Clamping Voltage: The TVSS shall able to clamp the voltage:

Magnetic Fields: The unit shall not generate any appreciable magnetic fields and shall suitable for use directly inside computer rooms. Connection type- Parallel Protection lvl in kV – based on level of protection Status indication – LED type dry contacts 7.3.3.11 Instruments & Relays a) Indicating instruments All electrical indicating instruments will be 96 mm square, with 240-degree scale (Taut band type). They shall be suitable for semi-flush with only flanges projecting on vertical panels. Instruments shall have accuracy class of 1.0 or better. The design of the scales shall be such that it can read to a resolution corresponding to 50% of the accuracy class index. KWH meter mentioned in the SLDs shall have pulse output to be integrated with the BAS system and an accuracy class of 1. b) Protective relays Protective relays shall conform to standard requirements. Type of relays either static or electro-mechanical which meet the various performance requirements are considered acceptable. All static relays shall be adequately protected against external voltage surges and 430

noise signals. In addition to this, all the input circuit of static relays will include their own auxiliary current and voltage transformers with screened windings. Where auxiliary interposing transformers are not feasible in the input circuit, relays would have special surge suppression circuits to suppress external noise and surges. Output elements of all static relays shall consist of electro-mechanical relays only. Relays shall have at least the following electrically independent output contacts for the following purposes: 

Tripping circuit



Remote / local annunciation If the main relay does not have sufficient number of output contacts inherently, these shall be multiplied using auxiliary relays. These auxiliary relays shall be used for annunciation, indication, etc. only. For tripping, only the contact of main relay shall be used directly

c) Wiring And Accessories Cubicles shall be completely wired upto equipment / terminal block. Interpanel and inter-cubicle looping of control and cubicle space heating supplies to be carried out by CONTRACTOR. Wiring to be carried out with 650V grade single core PVC insulated stranded copper conductor of following sizes : 

All circuits except CT circuit

:1.5 sq.mm.



CT circuit

:2.5 sq.mm.

Longitudinal troughs extending throughout the full length of the panels to be provided for interpanel wiring, AC-DC supplies, PT circuits, annunciator circuits, etc. Ferrules for wire termination to be provided. Wire connected to trip circuit will have red coloured ferrule. 7.3.3.12 Terminal Blocks a) Terminals blocks for CT and PT secondary leads shall be provided with test links and isolating facilities. b) All spare contacts and terminals of the panel mounted equipment and devices shall be wired to terminal blocks. At least 10% spare terminals shall be provided. c) Terminal blocks to be suitable for connecting the following conductors of the EMPLOYER‟s cables on each side: All circuits except CT circuit

Minimum of two 1.5 mm2 copper

CT Circuits

Minimum of four 2.5 mm2 copper

7.3.3.13 Cable Terminations a) Power and control cable glands and crimping type lugs shall be supplied to suit the cable sizes. b) Glands shall be heavy duty, double compression type made of brass and plated. 7.3.3.14 Control Supply

431

230/110V AC supply be provided for the switchgear. Suitable control transformer shall be provided to derive 110V AC control supply voltage. All inter panel wiring required shall be included in the scope. 7.3.3.15 Tests To Be Conducted a) Functional test, temperature rise test, high voltage test, limits of operation test, insulation test. EMPLOYER will have the option to witness the tests at the MANUFACTURER‟S work before dispatch. b) TENDERER shall furnish the type test certificates along with the Tender. In the absence of the same, the CONTRACTOR shall arrange to carry out the type test without any cost implication to the EMPLOYER. 7.3.3.16 List Of Drawings The CONTRACTOR shall furnish the following drawings for the switchgear: a)

Overall outline dimensions and general arrangement including plan, front elevation, rear & side elevations, clearances recommended in front and back.

The CONTRACTOR shall be entirely responsible for the correctness of the internal wiring diagrams



The CONTRACTOR shall ensure that the characteristics of the CTs, fuses, protection relays, VTs and all other devices offered by him are such as to be suitable for the purpose for which they are intended.

7.3.3.17 Test Certificates Type test certificates of all standard component parts, e.g. contactors, breakers, switches, fuses, relays, CTs, VTs, and for the standard factory built assembly shall be submitted by the CONTRACTOR. 7.3.3.18 Instruction Manuals The CONTRACTOR shall furnish specified number of copies of the instruction manual which would contain detailed instructions for all operational & maintenance requirement. The manual shall be furnished at the time of dispatch of the equipment and shall include the following aspects:

Rated voltages, current, duty-cycle and all other technical information which may be necessary for correct operation of the switchgear.

c)

Catalogue numbers of all components liable to be replaced during the life of the switchgear.

d)

Storage for prolonged duration.

e)

Unpacking.

f)

Handling at site.

g)

Erection.

h)

Precommissioning tests.

i)

Operating procedures.

j)

Maintenance procedures.

k)

Precautions to be taken during operation and maintenance work.

7.3.3.19 Installation The installation work shall cover assembly of various sections of the panels lining up, grouting the units etc. In the case of multiple panel switch boards after connecting up the bus bars etc., all joints shall be insulated with necessary insulation tape or approved insulation compound. A common earth bar as per these specifications shall be run inside at the back of switch panel connecting all the sections for connection to frame earth system. All protection and other small wirings for indication etc. shall be completed before calibration and commissioning checks are commenced. All relays, meters etc. shall be mounted and connected with appropriate wiring. 7.3.3.20 Testing And Commissioning Commissioning checks and tests shall include all wiring checks and checking up of connections. Relay adjustment/setting shall be done before commissioning in addition to routine Megger tests. Checks and tests shall include the following: a)

Operation checks and lubrication of all moving parts.

b)

Interlock function checks.

c)

Continuity checks of wiring, fuses etc. as required.

d)

Insulation test: When measured with 500V Megger the insulation resistance shall not be less than 100 mega ohms.

e)

Trip tests and protection gear test.

7.4 POWER FACTOR CORRECTION SYSTEM

433

7.4.1

Scope Design, manufacture, supply, erection, testing and commissioning of Indoor type power correction capacitor banks for power factor improvement as per specification given below.

7.4.2

Rating 50 KVAR (or less) capacitor units as specified in the BOQ shall be used to form a bank of capacitors of designed capacity.

7.4.3

Enclosure The panel shall be indoor type, free standing, and floor mounting with IP42 degree of protection. It shall be completely made of CRCA sheet steel. The enclosure shall have sturdy support structure with angle supports as necessary and shall be finished with powder coating in the approved colour shade/s to match the colour of the other panels. The thickness of powder coating should be minimum 80 microns. Suitable provisions shall be made in the panel for proper heat dissipation. Air aspiration louvers for heat dissipation shall be provided as a necessary. The front portion shall house the switchgear and the rear portion shall house capacitors . The enclosure is to be suitably sized to accommodate all the components, providing necessary air clearance between live and non-live parts, providing necessary working clearance.

7.4.4

APFC Relay / Controller Microprocessor based APFC relay (Intelligent VAr controller) shall sense the PF in the system and automatically switch ON / OFF the capacitor unit or stage to achieve the preset target PF. The controller shall have the following features : a) b) c) d) e) f)

7.4.5

Digital settings of parameters like PF, Switching time delay, Step limit etc. Indication of PF, preset parameters. Minimum threshold setting of 1% of CT current. No-volt release. Protective shut down in case of harmonic overload. Indication for Failure to achieve the target PF, Harmonic overloading, Step failure etc. g) All electricity supplies exceeding 100 A,3 phase shall maintain their power factor between 0.95 lag and unity at the point of connection. Capacitor Unit Each basic unit of mixed dielectric extra low loss heavy duty capacitor shall be built with a number of elements. These elements shall be combination of capacitor tissue paper and biaxially oriented polypropylene film impregnated with non PCB biodegradable impregnant or Film Foil capacitor manufactured using Poly propylene film placed between 2 layers of metal foil and winding. The elements shall be connected to the external bus bars through these leads in a series parallel connection to form a three phase unit. The capacitor units shall be floor mounting type using minimum floor space. The container of capacitors shall be made out of 2 mm thick M S sheet steel of polyster paint coated finish. Each standard unit shall be provided with internal fuses (operation co-ordinated with case-rupture characteristics to avoid rusting). Total Harmonic Distortion (THD) of upto 5% on voltage and current waveforms shall not affect the life of capacitors. ±10% variation in line voltage shall not affect the life of the capacitors. 434

7.4.6

Capacitors General specifications : 3 phase, delta connected, 50 Hz. Voltage : Shall be designed for minimum 520V and shall withstand system over voltage, increased voltage due to series reactor and harmonics. Capacitor type : Super heavy duty with double side metallised capacitor tissue paper. Oil impregnated and self-healing type with bi-axially oriented polypropylene film shall be fitted with pressure sensitive disconnector in each individual capacitor cell. Overvoltage +10% (12h / 24h), + 15% (30m / 24h), + 20% (5m), +30% (1m) as per Clause 6.1 of IS 13340-1993. Over current : 2.5 x In Pak Inrush current withstand : 350 x In Total watt-losses including discharge resistors : < 0.45 W / k V Ar. Temperature category : -25 deg.C to 70 deg.C. Capacitor shall be self-heating type and oil impregnated for longer life. The impregnant shall be non-PCB, biodegradable type, must be properly treated and degasified, so as not to have any degeneration properties and shall be non-oxidizing. The design shall be modular for simple mechanical assembly, no extra accessories / metal parts to be required. Unit must be free standing with an IP 41 protection level.

7.4.7

Discharge Resistance Capacitors shall be provided with permanently connected discharge resistors so that residual voltage of capacitors is reduced to 50 volts or less within one minute after the capacitors are disconnected from the source of supply.

Earthing Two separate earthing terminals shall be provided for earth connection of each bank.

7.4.10 Testing

The reactor shall be tested `using a separate source voltage test of 3 KV (coil to core) for one minute as per IEC 76/3. The reactor shall be fitted with a temperature sensitive micro-switch in the centre coil (normally open) for connection to trip circuit in case of high operating temperature. 7.4.11 Switchgear & Protection

Incomer switchgear shall be TP&N breaker appropriate rating (minimum 1.8 times the normal current to take care of inrush switching current). Suitable contactor for each step shall be used and must be capable of capacitor switching duty at each step for short circuit protection. Busbars shall be suitably colour coded and must be mounted on appropriate insulator supports. Power cables used shall have superior mechanical, electrical and thermal properties, and shall have the capability to continuously operate at very high temperatures up to 125 deg.C. 435

The control circuit shall be duly protected by using suitable rating MCB. Wiring of the control circuit shall be done by using 1.5 sq.mm, 1100 V grade, PVC insulated, multi-stranded copper control wire. Inspection terminal strip, number ferruling, labeling etc. shall be provided. 440 V caution board on the panel shall be provided. 7.4.13 Installation

Capacitors banks shall be installed as per installation manual of supplier and shall conform to relevant Indian Standards. All interconnections in the control panel shall be checked before commissioning. Cable end boxes shall be sealed after cable connections to prevent absorption of moisture. 7.4.14 Testing & Commissioning

The capacitor bank shall be subject to tests as specified in relevant Indian Standards at the factory and the test certificates shall be furnished in quadruplicate. Insulation resistance shall be tested with a 1000 volts meagger between phases and phase to earth. Residual voltage shall be measured after switching of the capacitors and the same shall not be more than 50 volts after one minute. Each discharge resistor shall be tested for its working.

7.5 TRANSFORMER - OIL TYPE: 7.5.1

Scope: Design, manufacture, testing, supply, Installation, testing and commissioning of outdoor type 33 kV /0.415 kV transformers with ONAN cooling complete with all the accessories and fittings for efficient and trouble free operation. The details are given in the data sheet. All other specifications shall be followed as per CPWD. First filling of oil shall be at site by contractor.

7.5.2 Standards: 7.5.2.1 The equipment and accessories covered by this specification shall be designed,

manufactured and tested in compliance with the latest relevant standards published by the Indian Standards institution wherever available in order that specific aspects under Indian conditions are taken care of. 7.5.2.2 The equipment and accessories for which Indian Standards are not available shall be designed, manufactured and tested in accordance with the latest standards published by any other recognized national standards institution.

436

7.5.2.3 The equipment shall also conform to the latest Indian Electricity Rules as regards

safety, earthing and other essential provisions specified therein for installation and operation of electrical plants. 7.5.3 General Design And Constructional Features: 7.5.3.1 All materials used shall be of best quality and of the class most suitable for working under the site conditions and shall withstand the variations of temperature and atmospheric conditions, overloads, over-excitation, short circuits as per applicable standards, without distortion or deterioration or the setting up of undue stresses in any part, and also without affecting the strength and suitability of the various parts for the work which they have to perform. 7.5.3.2 The design shall be such that the risks of accidental short-circuit due to birds or vermin‟s are obviated. All apparatus, including bushing insulators and fittings shall be so designed that water cannot collect at any point. Marshaling kiosks, boxes etc. shall be adequately ventilated to prevent condensation of moisture and so treated internally as to prevent growth of fungi on any coils, wires and insulating materials used. 7.5.3.3 The transformers shall operate with minimum noise and vibration. The cores, tank and other structural parts shall be properly constructed so that the mechanical vibrations are kept to the minimum, thus reducing the noise. 7.5.3.4 The design of the transformer shall be such that changes in transformer connection can be made by a simple change of link connection inside the tank. The transformers shall be designed to suppress harmonic voltages, specially the third and fifth, so as to eliminate distortion in wave form, and the possibility of circulating currents between the neutrals at different transformer stations. 7.5.3.5 All transformers shall be of the latest design, oil filled as called for in the main specification. All transformers shall be suitable for outdoor installation. The type of cooling and the corresponding ratings for each transformer shall be as indicated in the BOQ. 7.5.3.6 The magnetic circuit of each transformer shall be so designed as to minimize eddycurrent and hysteresis losses in the core. 7.5.3.7 All electrical connections and contacts shall be of ample section for carrying the rated current without excessive heating. 7.5.3.8 All mechanisms shall be of stainless steel, brass, gunmetal, or other suitable material to prevent sticking due to rust or corrosion. 7.5.4 Tank: 7.5.4.1 The transformer tank shall be made of steel plate, shaped in such a way that minimum of welding is required. The tank shall be electrically welded and all welding stresses shall be properly relieved. Tank walls shall be reinforced by adequate stiffeners to ensure mechanical rigidity permitting hoisting of complete transformers filled with oil and also to damp transformer noise. The tank shall be sufficiently strong to withstand shocks likely to be encountered during transport of the transformer without any deformation or weakening of joints. The joints shall be oil tight. Guides shall be welded on the inner side of the tank to facilitate tanking and untanking of the transformer core and coil assembly. 7.5.4.2 Tank cover shall be bolted on to the flanged rim of the tank with a suitable weather-proof, hot-oil-resistant gasket in between for oil tightness. The bolted tank cover shall be so arranged that it can be removed and the core inspected without removal of the radiators. All requisite access and inspection holes shall be provided with bolted oil tight, gasket seated cover plates. Bushing turrets, covers of access holes, covers of pockets to prevent leakage of water into the tank shall be provided. 7.5.4.3 The exterior of tank and other steel surface exposed to the weather shall be thoroughly cleaned and have a priming coat of zinc chromate applied. The second 437

coat shall be of an oil and weather resistant nature preferably of distinct colour from the prime and finish coats. The final coat shall be of a glossy, oil and weather resisting non-fading paint of specified shade. The interior of the tank shall be cleaned by shot blasting and painted with two coats of heat resistant and oil insoluble paint. 7.5.4.4 Steel bolts and nuts exposed to atmosphere shall be galvanized however; surfaces of the transformer or other parts of the transformer or auxiliary equipment which are in contact with oil shall not be galvanized. 7.5.4.5 The transformer tank, auxiliary equipment and fittings shall be provided with necessary devices for lifting and haulage facilities. The tank shall be mounted on a substantial under-carriage. 7.5.4.6 Unless otherwise stated the tank together with radiators, conservator, bushings and other fittings shall be designed to withstand without permanent distortion the following conditions. a) Full vacuum of 760mm of Hg for filling oil by vacuum. b) Internal gas pressure of 0.35 Kg/Sq.cm. with oil at operating level. c) Valves shall not leak nor any welded joints sweat under above conditions. 7.5.4.7 Adequate space shall be provided at the bottom of the tank for collection of sediments. 7.5.5 Core: 7.5.5.1 The magnetic circuit shall be built of transformer grade cold rolled grain oriented low loss steel stampings having high permeability and conforming to adopted standards. Stampings shall be insulated from each other with material having high interlamination insulation resistance and rust inhibiting property and also capable of withstanding pressure, mechanical vibration and action of heat and oil, thus reducing the possibility of sludge formation to a minimum. 7.5.5.2 The framework, clamping arrangement and general structure of the cores of each transformer shall be of robust construction and shall be capable of withstanding any shock to which they may be subjected during transport, installation and service. The assembled core shall be securely clamped, on the limbs and the yoke, to build up a rigid structure. The clamping pressure shall be uniform over the whole of the core and so adjusted as to minimize noise and vibration in the core when the transformer is in service. The framework and the core bolts shall be efficiently insulated from the core so as to reduce the circulating currents to a minimum. 7.5.5.3 The core clamping frame shall be provided with lifting eyes for the purpose of tanking and untanking the core with winding mounted thereon and shall have ample strength to take the full weight of the core and winding assembly. 7.5.5.4 An approved type of core grounding system shall be used; the grounding connections being located at the top of the core for easy access from the inspection hole. 7.5.6 Winding: 7.5.6.1 The coils used for transformer winding shall be flat in shape, made of paper insulated, continuous and smooth, tinned or enameled electrolytic copper conductors of high conductivity. 7.5.6.2 The transformer winding shall be designed for basic impulse insulation level not lower than that specified in the main specification. 7.5.6.3 Liberal ducts shall be provided to prevent any hot spot temperature in the winding that may adversely affect the life of the transformer. Adequate supports, wedges and spacers of hard insulating material shall be so fitted that they will neither move nor permit relative movement of any part of winding during transit of normal service or under terminal short circuit, nor damage the winding insulation in any way. All leads and connections shall be robust, adequately insulated, protected and clamped. The winding assembly shall be dried in vacuum with tested insulating oil of approved 438

standard. The windings shall be subjected to a thorough shrinking and seasoning process so that no further shrinkage of windings occur during service at site. However adjustable devices shall be provided for taking up any possible shrinkage of coils in service. The assembly shall be held in position under adequate axial compression to withstand the axial thrust likely to occur under terminal short circuit. 7.5.6.4 The end turns on the high voltage winding shall have reinforced insulation to take care of the voltage surges likely to occur during switching or any other abnormal system condition. 7.5.6.5 The transformers shall be suitable for operation at full rated power on all tappings without exceeding the specified temperature rise as indicated in the applicable standards. 7.5.7 Insulating Materials: The insulating oil shall conform to IS-335 and shall be suitable in all respects for operating the transformer at the rating and under conditions specified in the main equipment specification. Sufficient oil shall be supplied for the first filling of transformer, the oil circulating equipment and the tank containing tap-changing mechanism and an extra 10% shall be supplied in non-returnable drums. The tender shall contain information about the grades of oil recommended by the transformer manufacturer for use in the transformer. Test certificates for the oil shall be furnished before dispatch of transformer and acceptance by Employer. 7.5.8

Transformer Tappings: 33/4.415 kV, delta / star wound, Transformers shall be with on load tap changer. Transformer shall be provided with „ON‟ load tap changing on 33 KV side. The tapings to be provided for variation on HV side from +7.5% to – 7.5% in steps of 1.25% each. Provision of bushing shall be made for neutral and neutral CTs shall also be provided.

7.5.9

Cooling Equipment: Natural cooling by means of banks of detachable type radiators made from pressed/round tubes around transformer tank shall be provided. The radiators shall be of seamless mild steel sheet with clean bright internal surface and shall be suitably braced to protect them from shock.

The disconnecting chamber shall be air insulated and complete with seal off bushing, removable flexible connectors / links and removable covers. It shall be possible to trail out the transformer without having disconnecting the bus duct / cables.

439

Phase to phase and phase to ground clearances within the chamber shall be such as to enable either the transformer or cable to be subjected separately to H.V. test. 7.5.10.4Bushing:

Whenever optional fittings, temperature indicators, with auxiliary contacts, Buchholtz Relay and Bushing CT's are specified then the bidder shall provide a Marshalling box and Marshall to it all the contact terminals of electrical devices mounted on the transformer. It shall be in the contractor's scope to provide: a)

b)

The interconnection cabling between the Marshalling box and the accessory devices either by PVC insulated copper wire in G.I. conduits or PVC insulated copper conductor armoured cables. Necessary compression type brass cable glands at the Marshalling box for above cables.

The Marshalling box shall be tank mounted, water/dust tight sheet steel (2mm thick) enclosed with hinged door having padlocking facility. All doors, covers and plates shall be fitted with neoprene gaskets. Top surface shall be sloped and bottom shall be atleast 600mm from floor and provided with gland plate and cable glands as required. Terminals shall be clipon type rated for 10A. All contacts for alarm/trip indication shall be potential free, wired up to the terminal block. Wiring shall be done with stranded copper conductor wires of sizes not less than 1.5 sq.mm for control and 2.5 sq.mm for CT circuits. C.T. terminals shall be provided with shorting facility. 7.5.12 Electrical & Performance Requirement:

Transformer shall operate without injurious heating at the rated kVA at any voltage within +/- 10% of the rated voltage of that particular tap. Transformer shall be designed for 110% continuous over fluxing withstand capability. The neutral terminals of the winding with star connection shall be designed for the highest over current that can flow through the winding. Overloads shall be allowed within the conditions defined in the loading guide of the applicable standard. Under these conditions, no limitations by terminal bushings, tap changers or other auxiliary equipment shall apply. Temperature Rise shall be continuously rated for full load. The temperature rise shall not exceed 45 degree C by thermometer in oil or 55 degree centigrade by resistance over an ambient of 38 degree C. 7.5.13 Earthing: 7.5.13.1Two separate earthing terminals to be provided at the bottom of the tank on opposite

sides. The terminals shall be suitable for connection to grounding strip. 7.5.13.2Internal Earthing:

The frame work and clamping arrangements of core and oil shall be securely earthed inside the tank by adequately sized copper strip connections to the tank. 7.5.14 Fittings And Accessories: 440

The transformer shall be provided with all standard fittings and accessories specified in the applicable standard for the size and type of transformer concerned. The accessories and fittings shall generally be as specified below: a)

Lifting Lugs: The arrangement for lifting the active part out of the transformer tank along with the cover by means of lifting lugs without disturbing the connections.

b)

Swivel Type Rollers: The transformer to be provided with 4 No‟s Bi-Directional rollers fitted on cross channels to facilitate the movement of the transformer in both directions.

c)

Oil Conservator: The transformer to be provided with an oil conservator with welded end plates. It is to be bolted to the cover and can be dismounted for purpose of transport. It has to be provided with magnetic oil level gauge and an oil filling hole 1 1/4” BSF size with a cap, which can be used for filtering oil. For draining purpose a plug shall provided. A connection pipe between the conservator and the main tank is to be provided which projects inside the conservator and the main tank is to be provided which projects inside the conservator.

d)

Air release Valve: An air release valve is to be provided on the top of the tank cover facilitate the release of the entrapped air and filling of oil.

e)

Breather: The transformer to be provided with an indicating dehydrating silica gel breather of sufficient capacity.

f)

Drain-cum-oil Filter Valves: The transformer to be provided with a drain-cum-oil filter valve of 1 1/4” BSF size at the bottom of the tank.

GA drawing showing dimension, net weight and shipping weight, quantity of insulating oil etc. Suitable capacity of crane requirements for assembly and dismantling of the transformer. Drawing indicating GA of busduct/cable box and its dimension for cable entry cut out requirements etc. The drawings in (four sets) to be furnished by the supplier for approval after acceptance of his order shall include the following. GA showing front and side elevations and plan of transformer and all accessories and external features, detailed dimensions, crane lift for untanking, oil quantity, H.T./L.T. clearances etc. Drawings of Bus duct/cables termination arrangement. HV cable box arrangement & disconnecting chamber GA & details drawings. Drawing of each type of bushing. Name plate and terminal making and connection diagram. Control wiring & schematic diagram showing polarity and vector group of windings, CTs and OTI, WTI, circuits, Alarm/trip circuits etc. Reproducible copy of the above drawings for records Maximum allowable Power losses shall be as per ECBC norms. 7.5.16 Testing:

The transformer shall be subjected to all routine tests in accordance with IS : 2026 at the factory before dispatching the same and test certificates shall be furnished. Testing at site: a) b) c)

Four copies of the test reports in bound volume shall be submitted for approval. SOAK PIT AND DRAIN PIT (Wherever required) shall be provided as per IS 10028- 2. The transformers foundation shall be surrounded by a suitable soak pit enclosed by a 150 mm high non- combustible curb. This soak pit shall be filled with coarse crushed stones about 25mm in diameter to a minimum depth of 300 mm. The volume of the soak pit minus the volume of the stones should be sufficient to contain the entire oil content of the transformer if the oil content is less than or equal to 5 kl. In case the oil content is more than 5 kl, the volume of soak pit minus the volume of stones should be sufficient to contain at least one third of the total oil content. The excess should be led through two or more hume /concrete pipes (min. 150 dia.) from bottom of pit to a central remote burnt oil tank. 7.5.17 Remote Tap Changer Control Panel (RTCC) for 33/0.415kV, 2 MVA transformer

RTCC panel shall be of sheet steel cabinet for indoor installation, floor mounting type. The RTCC panel shall be totally enclosed, completely dust and vermin proof and shall be with hinged doors, Neoprene gasket and padlocking arrangement. RTCC panel shall be suitable for the climatic conditions as specified in Special Conditions. Steel sheets used in the construction of RTCC panel shall be 14 SWG 442

CRCA sheet steel and shall be folded and braced as necessary to provide a rigid support for all components. Joints of any kind in sheet metal shall be seam welded, all welding, slag shall be rounded off and welding pits wiped smooth with plumber metal. The general construction shall confirm to IS-8623-1977 (part-I) for factory built assembled switchgear & control gear for voltage upto and including 1100 V AC. All panels and covers shall be properly fitted and square with the frame, and holes in the panel correctly positioned. Fixing screws shall enter into holes tapped into an adequate thickness of metal or provided with wing nuts. Self threading screws shall not be used in the construction of RTCC panel. A base channel of 75 mm x 40 mm x 5 mm thick shall be provided at the bottom for floor mounted panel. The following components shall be provided in the RTCC panel: a) b) c) d) e) f) g) h) i) j) k)

Scope: The specification covers design, manufacturing, supply, installation, testing and commissioning of Sandwich type busbar trunking for use as feeder busbars for interconnection between separate electrical equipment / load centers, and for use as plug in busbar risers.

7.6.2

System details: The busbar shall be suitable for operation in a 600V system, with frequency of 50 Hz having 100% neutral and internal earth. The bus duct shall conform to IEE/NEMA/BUI/JIS for seismic protection certification.

The busbars shall be of sandwich construction, non-ventilated design. It shall be possible to mount the busbar system in any orientation, without affecting the current rating. The bus duct shall consist of three phases and neutral bus bar permanently positioned dust and vermin proof and the degree of enclosure protection shall be IP 52 for 443

indoor installation and shall be IP-65 for outdoor installation as per schedule of quantities. 7.6.3.2 Busbars:

The busbars shall of high conductivity Copper, or Aluminum, as specified in the tender. Where an earth conductor is required, it shall be a separate, integral earth conductor, of the same high conductivity material as the phase conductors. 7.6.3.3 Insulation:

The busbars shall be insulated throughout their length by epoxy coating / Mylar. The insulation material used shall be of Class H (180 deg. C). The insulation must comply to UL 94 V-O. It shall be Halogen Free. Housing: The housing shall be made of extruded Aluminum case duly enameled/ electro-galvanized sheet steel, with an epoxy powder coated paint finish. The housing shall be profiled, to provide higher strength and efficient heat dissipation. The width of the housing shall preferably be the same for all ratings of busbars, in order to provide interchangeability of tap off boxes. 7.6.3.4 Joints:

The joints between sections shall be made so as to provide flexibility during installation and expansion / contraction of busbar during operation. The joints shall be of the single bolt type The joint construction must have the following features. a) b)

Heat expansion of at least 3mm per joint. The joint insulation must be of one piece molded design and not have any cut edges which can absorb moisture. c) The joint construction must allow a +/- 14mm adjustment at the time of installation, for ease of adjusting to site measurement variations. d) The joint bolt must be insulated with a bolt insulator. The bolt insulator must be of molded one piece. e) The joint system must be designed in a way that the installer cannot insert the busduct length too far and damage the bolt insulator. f) The busbar ends shall not have holes or slots at the joints – the electrical continuity shall be through pressure plates, achieving a high area of joint cross section and expansion capability. g) It shall be possible to install and remove the joints without disturbing the busbar run. 7.6.3.5 End termination: At the termination either on the transformer side or on the panel side , bus duct shall be provided with flange ends, adopter box and copper flexible( preferably multi sheet types) to connect bus bar of bus duct to bus bar of panels or transformer terminals. 7.6.3.6 Accessories:

A full range of accessories like bends, end flanges, end feed units, and support brackets etc. shall be available. 7.6.4

Installation Bus ducts running along the wall shall be supported at intervals not exceeding 1.5 m. In case of branching, there shall be support on all branches at a distance of 300 mm 444

from the point of branching, Support shall not be less than 40 x 40 x 6 mm MS angle secured in an approved manner. Supports may also be provided in the form of brackets fixed to walls where the duct runs along the wall. In case of ceiling suspended bus ducts, supports made out of 40x40x6 mm MS angle iron shall be provided along with 12mm dia MS rod with threading and nut bolts. The horizontal distance between two such supports shall not be more than 1200 mm. The ducts supports shall be suspended from suitable approved suspension devices provided in the ceiling. Fire barrier shall be provided at each floor/wall crossing as per relevant IS code. Continuous earth bus of suitable size shall be provided along with throughout the length of Bus duct. Fire barrier of 2hrs rating shall be provided on each floor. 7.6.5

Testing The busbars shall be type tested at a reputed international test laboratory (ASTA or CPRI) for short circuit withstand. The test shall be for a minimum duration of 1 second. Tests shall be performed over a range of current ratings, covering the different frame sizes of the manufacturer. Degree of ingress protection (IP rating) shall also be tested at any reputed independent laboratory. This test shall be for IP54 for indoor application and IP65 for outdoor application for sandwiched busbars. The following tests shall be carried out at site and test results to be recorded: a) b)

Insulation resistance shall be tested with 1000 V megger and shall be not less than 100 mega ohms. Earth continuity test

Material Conductor The Conductor shall be made from electrical grade aluminum, stranded wires compacted together. Insulation High quality TROPOTHEN - X (XLPE) unfilled insulating compound of natural colour shall be used for insulation. Insulation shall be provided by extrusion process and shall be chemically cross linked in continues vulcanization process. Shielding Cables shall be provided with conductor shielding as well as insulation shielding and shall consist of extruded semi-conducting compound, additionally insulation shield shall be provided with semi-conducting and metallic tape shield over the extruded 445

insulation shield. XLPE insulation and outer core shielding shall be extruded in one operation. Armoring Armoring shall be provided over the inner sheath and shall comprise of flat steel wires (strips). Outer Sheath (with FRLS) Tough outer sheath of heat resisting PVC compound shall be FRLS extruded over the armoring in case of armored cables, or over inner sheath in the case of unarmored cables. 7.7.3

Tests Cables shall be type tested and routine tested in accordance with IS:7098 (Part II). The following tests shall be carried out at site for insulation between phases and between phase and earth before and after the cable laying is complete. a) b) c) d) e)

Cables shall be laid with a clearance of at least 75 mm between two cables. Before laying of cables megger values shall be taken and shall be recorded. 7.7.4

End Termination of HT Cable Pre-moulded cable terminations for XLPE cable shall be used as per manufacturer‟s instructions. The heat shrinkable raychem shall consist of highly track resistant insulating section vulcanised to a semi-conducting section. The pad material shall have cold-flow properties and shall be flame retardant. Each end terminal shall undergo Hi Pot Test at site. Necessary equipment shall be arranged at site by contractor.

7.7.5

Laying of HT Cables Direct In Ground The work shall involve digging of outdoor trench in ground and laying cable(s) as indicated in specifications and Schedule of Quantities. The depth of the trenches shall not be less than 1200 mm for 33 KV , 900mm for 11kV plus radius of cable, from the upper surface of ground. Where more than one multicore cable is laid in the same trench, a horizontal inter spacing of 250 mm shall be left in order ro reduce mutual heating and also to ensure that fault occuring on one cable will not damage the adjacent cable. Cable shall be laid in cement pipes encased in concrete or hume pipes at all road crossing. Cables shall be laid in trenches over rollers placed inside the trenches. After the cable has been properly laid and straightened, it shall covered with 80 mm thick layer of sand. Cable shall then be lifted and placed over the sand cushion. Again, the cable shall be covered with 80 mm layer of sand. Over this cable protection shall be provided by providing tiles which shall overlap cables 50 mm on either side. Trenches shall then be back-filled with earth and shall be consolidated. Suitable cable markers made of cast iron with aluminium paint indicating the voltage grade, direction of run and size of cables shall be provided at regular intervals. 446

Standards Of Codes This chapter covers the specifications for supply and laying of Medium Voltage XLPE insulated PVC sheathed FRLS cables for 1100 volts. All equipments, components, materials and entire work shall be carried out in conformity with applicable and relevant Bureau of Indian Standards and Codes of Practice, as amended upto date. In addition, relevant clauses of the Indian Electricity Act 1910 and Indian Electricity Rules 1956 as amended upto date shall also apply. Wherever appropriate Indian Standards are not available, relevant British and /or IEC Standards shall be applicable.

7.8.2

Cables Medium voltage cables shall be aluminium/copper conductor XLPE insulated, FRLS PVC sheathed, armoured conforming to latest IS. Cables shall be rated for 1100 Volts. All Conductor cables shall be as per BOQ. Conductors shall be insulated with high quality XLPE base compound. A common covering (bedding) shall be applied over the laid up cores by extruded sheath of unvulcanised compound. Armouring shall be applied below outer sheath of PVC sheathing. The outer sheath shall bear the manufacturer‟s name and trade mark at every meter length. Cores shall be provided with following colour scheme of PVC insulation.

7.8.3

1 Core

:

Red/Black/Yellow/Blue

2 Core

:

Red and Black

3 Core

:

Red, Yellow and Blue

3 ½ /4 Core

:

Red, Yellow, Blue and Black

LAYING Cables shall be laid as per the specifications given below : 447

7.8.3.1 Duct system

Wherever specified such as road crossing, entry to building or in paved area etc. cables shall be laid in underground ducts.

The duct system shall consists of a

required number of stone ware pipes, GI, CI or spun reinforced concrete pipe with simplex joints and all the jointing work shall be done according to the CPWD building specifications or as per the instructions of the Engineer-In-Charge as the case may be. The size of the pipe shall not be less than 100mm in diameter for a single cable and shall not be less than 150mm for more than one cable and so on. The pipe shall be laid directly in ground without making any special bed but wherever asbestos cement pipes are used, the pipes shall be encased in concrete of 75mm thick. The ducts shall be properly anchored to prevent any movement. The top surface of the cable ducts shall not be less than 60 cm. below the ground level. The ducts shall be laid a gradient of at least 1:300. The duct shall be provided manholes of adequate size at regular intervals for drawing the cables. The manhole cover and frame shall be of cast iron and machine finished to ensure a perfect joint. The manhole covers shall be installed flush with the ground or paved surfaces. The duct entry to the manholes shall be made leak proof with lead-wool joints. The ducts shall be properly plugged at the ends to prevent entry of water, rodents, etc. Suitable duct markers shall be placed along the run of the cable ducts. The duct markers shall at least be 15 cm. square embedded in concrete, indicating duct. Suitable cable supports made of angle iron shall be provided in the manholes for supporting the cables. Proper identification tags shall be provided for each cable in the manholes. 7.8.3.2 Cables in outdoor trenches

Cable shall be laid in outdoor trenches wherever called for. The depth of the trenches shall not be less than 75cm from the final ground level. The width of the trenches shall not be less than 45 cm. However, where more than one cable is laid, an axial distance of not less than 15 cm. shall be allowed between the cables. The trenches shall be excavated in reasonably straight line with vertical side walls and with uniform depth. Wherever there is a change in direction suitable curvature shall be provided complying with the requirements. Suitable shoring and propping may be done to avoid caving in of trench walls. The bottom of the trench shall be level and free from stone brick bats etc. The trench shall then be provided with a layer of clean, dry sand cushion of not less than 8 cm. in depth.

448

The cable shall be pulled over rollers in the trench steadily and uniformly without jerks and strains. The entire cable length shall as far as possible be paved of in one stretch. However where this is not possible the remainder of the cable may be removed by "Flaking" i.e. by making one long loop in the reverse direction. After the cable has been uncoiled and laid into the trench over the rollers, the cable shall be lifted slightly over the rollers beginning from one end by helpers standing about 10 mtrs. apart and drawn straight. The cable should then be taken off the rollers by additional helpers lifting the cable and then laid in a reasonably straight line. For short cut runs and sizes upto 50 sq.mm of cables upto 1.1 KV grade any other suitable method of direct handling and laying can be adopted with the prior approval of the Engineer-in-charge. When the cable has been properly straightened, the cores are tested for continuity and insulation resistance and the cable length then measured. The ends of all cables shall be sealed immediately. In case of PVC cables suitable moisture seal tape shall be used for this purpose. Cable laid in trenches in a single tier formation shall have a covering of clean, dry sand of not less 17 cms above the base cushion of sand before the protective cover is laid. In the case of vertical multi tier formation after the first cable has been laid, a sand cushion of 30 cms shall be provided over the initial bed before the second tier is laid.

If

additional

tiers

are formed, each of the subsequent tiers also shall have a sand cushion of 30 cms as stated above. The top most cable shall have final sand covering not less than 17 cms before the protective cover is laid. Unless otherwise specified, the cables shall be protected by the second class bricks of not less 20 cms x 10 cms x 10 cms (nominal size) protection covers placed on top of the sand (bricks to be laid breadth wise) for the full length of the cable. Where more than one cable is to be laid in the same trench, this protective covering shall cover all the cables and project at 5 cm. over the sides of the end cables. The trenches shall be taken back filled with excavated earth free from stones or other sharp edge debris and shall be rammed and watered, if necessary, in successive layers not exceeding 30 cm, unless otherwise specified. 7.8.3.3 Route Marker

449

Cable route marker marked "Cable" shall be provided alongwith the route of the cable and location of loops. The route markers shall be of tapered concrete slab of 60 x 60cm at bottom and 50 x 50cm at top having a thickness of 10cm. Cable marker shall be mounted parallel to and 50cm away from the edge of the trench. 7.8.3.4 Cables in indoor trenches

Cables shall be laid in indoor trenches wherever specified. The trench shall be made of brick masonry with smooth cement mortar finish with suitable removable covers (i.e. precasted slabs or chequred plates). The dimensions of the trenches shall be determined depending upon the maximum number of cables that is expected to be accommodated and can be conveniently laid.

Cables shall be arranged in tier

formation in trenches and if necessary, cables may be fixed with clamps. Suitable clamps, hooks and saddles shall be used for securing the cables in position. Spacing between the cables shall not be less than 15 cm centre to centre. Wherever specified, trenches shall be filled with fine sand and covered with RCC or steel chequred trench covers. 7.8.3.5 Cable on Trays/Racks

Cable shall be laid on cable trays/racks wherever specified. Cable racks/trays shall be of ladder, trough or channel design suitable for the purpose. The nominal depth of the trays/racks shall be 150 mm. The width of the trays shall be made of steel or aluminium. The trays/racks shall be completed with end plates, tees, elbows, risers, and all necessary hardware, entire steel trays/ racks shall be hot dip galvanized including widths & accessories. Cable trays shall be erected properly to present a neat and clean appearance. Suitable cleats or saddles made of aluminium strips with PVC covering shall be used for securing the cables to the cable trays. The cable trays shall comply with the following requirements : The tray shall have suitable strength and rigidity to provide adequate support for all contained cables. a)

It shall not present sharp edges, burrs or projections injurious to the insulation of wiring/cables.

b)

If made of metal, it shall be adequately protected against corrosion or shall be made of corrosion-resistant material.

c)

It shall have side rails or equivalent structural members.

450

d)

It shall include fittings or other suitable means for changes in direction and elevation of runs.

7.8.4

Installation Cable trays shall be installed as a complete system.

Trays shall be supported

properly from the building structure. The entire cable tray system shall be rigid. Each run of the cable tray shall be completed before the installation of cables. In

portions

where

additional

protection

is

required,

non

combustible

covers/enclosures shall be used. Cable trays shall be exposed and accessible. Where cables of different system are installed on the same cable tray, non combustible, solid barriers shall be used for segregating the cables. Cable trays shall be grounded by two nos, earth continuity wires. Cable trays shall not be used as equipment grounding conductors. At no place the cable tray / rack / ladder running horizontally should rest on any building partition like Brick wall, RCC beams etc. but instead proper MS supports/ hangers to be provided at minimum of 1500 mm intervals and at every Turning Angles. 7.8.5

Jointing and termination‟s Cable jointing shall be done as per the recommendations of the cable manufacturer. All jointing work shall be done only by qualified/licensed cable jointer. All jointing pits shall be of sufficient dimensions as to allow easy and comfortable working. Jointing materials and accessories like conductor, ferrules, solder, flex, insulating and protective tapes, filling compound, jointing box etc. of right quality and correct sizes, confirming to relevant Indian Standards. Each termination‟s shall be carried out using brass compression glands and cable sockets. Hydraulic crimping tool hall be used for making the end termination‟s. Cable gland shall be bonded to the earth by using suitable size copper wire/tape.

services shall be with additional FRLS properties. The cables shall conform to IS1554 - Part - I (1988). For multicore cables, fillers used to fill in the space between the phases shall be non-hygroscopic, chemically inert and non-putrescent. Cables laid outside the building, either buried or in trench shall be of armoured type. 7.8.7

Design Criteria For Cable Sizing Power cables shall be selected on the following basis: a)

Power cable shall carry the full load current of the circuit continuously

under site conditions considering the various derating factors like ambient

air

temperature (50 deg C), grouping, laying methods etc. b)

Power cables shall be sized to restrict the voltage drop to 5% and a voltage

dip of 10% for motors. c)

Power cable shall withstand the fault current of the circuit for the duration

not less than the maximum time taken by the primary

protective

system

to

isolate the fault. 7.8.9

Testing of Cables Cables shall be tested at works for all routine tests as per IS including the following tests before being dispatched to site by the project team. Insulation Resistance Test. Continuity resistance test. Sheathing continuity test. Earth test.(in armoured cables) Hi Pot Test.

452

Test shall also be conducted at site for insulation between phases and between phase and earth for each length of cable, before and after jointing. On completion of cable laying work,

all expenses in connection with such tests. All tests shall be carried out in the presence of the Engineer In charge/ his representative, results will be noted and signed by all present and record be maintained. All the test certificate shall be submitted by contractor.

Zinc to be used shall conform to minimum Zn 98 grade as per requirement of IS:2091992. 7.9.3.2 Coating Requirement

Minimum weight of zinc coating for mild steel flats with thickness upto 6 mm in accordance with IS:6745-1972 shall be 400 g/sqm. The weight of coating expressed in grams per square metre shall be calculated by dividing the total weight of Zinc by total area (both sides) of the coated surface. The Zinc coating shall be uniform, smooth and free from imperfections as flux, ash and dross inclusions, bare patches black spots, pimples, lumpiness, runs, rust stains bulky white deposits, blisters. Mild steel flats / wires shall undergo a process of degreasing pickling in acid, cold rinsing and then galvanizing. The thickness of galvanizing shall be 610 gm / Sq. mtr. (87 Microns) in line with IS: 4759 All finished cable trays and accessories shall be free from sharp tees, corners, burrs and unevenness. 454

7.9.3.3 Cable Trays - Installation Notes

Cable trays shall be installed generally at the elevations shown in respective cable tray layout drawings. If any major modifications in the drawings are envisaged in the field, these should be carried out after getting approval from design office. Before laying the trays, contractor shall submit the shop drawing & take the approval from client/Project Manager. It shall be the responsibility of the electrical contractor to mark up all the field modifications on the latest issues of the drawings and return two copies of all such “ as constructed ” drawings to client/Project Manager‟s design office. The type and size of tray to be used shall be as mentioned in the individual layout drawings. Cable trays shall be welded to the mounting/carrier structures. Trays shall be supported with suitable angle/hitech rod supports. Each continuous laid out length of cable tray shall be earthed at minimum two places by GI flats of minimum size 25x6 mm (unless otherwise noted) to the Employer‟s earthing system. The distance between earthing points shall not exceed 10 meters. The following shall be checked before laying the cables on trays. a)

Check for proper identification nos. of the trays.

b)

Check for continuity of cable trays over the entire route.

c)

Check that all sharp corners, burrs and waste materials have been removed from the tray.

d)

Obtain clearances from piping contractor / engineer that no piping will be taken in the way of cable trays.

e)

Check for earth continuity & earth connection of cable trays.

f)

Cable tray installation work shall comply with all currently applicable statutes, regulations and safety codes in the locality/country where the installation is to be carried out.

7.10 LIGHTING SYSTEM 7.10.1 Scope

This specification covers the design, material specification, manufacture, testing, inspection and delivery to site installation, testing and commissioning of lighting system equipment such as lighting fixtures, light control switches, receptacle units, lighting wires, lighting poles, conduits and other similar items necessary for lighting system. Customer / Architect shall have final authority to select light fittings. 7.10.2 STANDARDS

The items of supply and installation shall comply with the latest applicable standards as specified in specification, Notes and Details and lighting layout drawings. Where no standards are available, the supply items shall be backed by test results shall be of 455

good quality and workmanship and any supply items which are bought out by the CONTRACTOR shall be procured from approved manufacturers acceptable to the EMPLOYER. 7.10.3 LIGHTING FIXTURES AND ACCESSORIES 7.13.3.1Lighting Fixtures / Luminaries – General Requirements:

a)

Luminaries shall be designed for continuous trouble-free operation under atmospheric conditions without reduction in lamp life or without deterioration of materials and internal wiring. Outdoor fittings shall be weatherproof and waterproof.

b)

All Luminaries shall be supplied complete with lamps suitable for operation on a normal supply voltage and the variation in supply voltage and frequency indicated in data sheet.

c)

Fluorescent T5 type, sodium vapour and metal halide type Luminaries shall be complete with accessories like lamps, ballasts, power factor improvement capacitors, starters etc. These shall be mounted as far as possible in the Luminaries housing only. If these cannot be accommodated integral with the Luminaries then a separate metal enclosed control gear box shall be included to accommodate the control accessories together with a terminal block suitable for loop-in, loop-out connections. Outdoor type fixtures shall be provided with outdoor type weatherproof box with IP 55 or better.

d)

Fluorescent type Luminaries with more than one lamp shall be provided with capacitors connected in lead-lag circuit for correction of stroboscopic effect.

e)

Each Luminary shall have a terminal block suitable for loop-in, loop-out and T-off connection. Terminals shall be of stud or clamp type. Terminal blocks shall be mounted with minimum two fixing screws.

f)

Mounting facility and conduit knockouts for the Luminaries shall be provided.

g)

All hardware used in the Luminaries shall be suitably plated or anodised and passivated for use in chemical, industrial and power plants.

h)

Earthing Each Luminaries and control gearbox shall be provided with an terminal suitable for connection earthing conductor as indicated.

i)

earthing

Painting / Finish All surfaces of the luminaries / control gearbox housing accessories shall be thoroughly cleaned and degreased. It shall be free from scale, rust, sharp edges and burrs. The finish of the luminaries shall be such that no bright spots are produced either by direct light source or by reflection.

The LEDs shall be of reputed make such as OSRAM / Philips / Lumileds / Cree/ Nichia. 456

b) c) d) e) f) g) h)

i) j)

k)

l) m)

n)

o) p)

q)

r)

s) t)

u) v)

LED fixtures to be utilized for Utility area and Street lighting. LED module/ array shall deliver at least 85 % of initial lumens, when installed for a minimum of 50,000 hours. To enhance the secondary optics of the fixture, suitable Acrylic Optical Lenses shall be used. The Correlated Color Temperature (CCT) of the LED fixture shall be in the range of 5500-6000°K. The luminaries shall ensure a CRI of minimum 70. The Uniformity Ratio (Emin /Eavg) shall be mimimum of 60%. The LED luminaries shall produce constant lux level in the voltage range of 140V to 280V. Voltage variations/ fluctuations in the specified voltage range shall not impinge upon the lux level it produces. The life span of the LED source including its Driver shall be minimum or greater than 50000 hours. The P/N junction temperature of individual LED must not exceed 100ºC. High Thermal conduction must be achieved by use of silicon heat conductive greases an adhesive. LED Light must be constructed to achieve the average illumination of 35 LUX and at the ground level/ working level for the all the Utility Plants roads with the Uniformity Ratio (Emin /Eavg) of mimimum of 60% and tranverse ratio (Emin/Emax) of 0.4 as per relevant to the employers requirement. All fasteners must be of stainless steel and rustfree. LED must be mounted on heat sinking conductive bars if any with suitable large area surface by means of fins to dissipate the conducted heat. The fins must be exposed to ambient flowing air. Heat sink used should be aluminium extrusion / high pressure die cast aluminium having high conductivity. Heat sink should be integrated within luminaire and efforts shall be made to keep the overall outer dimensions optimum such that it permits sufficient heat dissipation through the body itself so as to prevent abnormal temperature inside the luminaire and consequential damage to cover, gasket material, LEDs, lenses and drivers. The electrical component of the LED and LED driver must be suitably enclosed in hermetically sealed unit. In addition, LEDs should be voltage control dimmable with provision for power line communication modem or other standard communication system which shall be able to communicate with electronic drivers or similar type of lighting controllers and operate without generating excessive heat. All the LEDs should be “on” while dimming The luminary should be provided with in-built power unit & electronic driver. The luminary should be so constructed to ensure that the drivers are replaceable, if required. The luminaries shall conform to IEC 60598 or equivalent standard. The driver should comply with IEC 61347-2-13, IEC 61547, CISPR-15; and 61000-3-2. The supplier should submit luminary test report conforming to the specified standards. Light Distribution shall be of Cut Off/ Semi Cut Off type. Each lighting fixture shall be provided with an earthing terminal suitable for connecting 2.5 sq. mm (1 core of the 3Cx2.5 sq. mm copper-PVC cable to be used) copper stranded conductor. Applicable standards The standards and code of practices referred to below shall be the latest editions Including all official amendments and revisions. 457

w) x) y) z) aa) bb)

General safety requirements: IS 1913 - for luminaries Luminaries for street lighting: IS 10322 - electric cables Current waveform for the LED drivers should meet relevant national and international standard. Electronic components IC (Integrated circuit) shall be of industrial grade or above. Metallic film/ Paper/ Polyester Capacitor shall be rated for a sustained operating temperature of 105° C. The construction of PCBs and the assembly for components for PCBs should be as per IS standards.

7.10.4 Construction

a)

The casing of the lighting luminaries shall be made of pressure die cast aluminum coated with epoxy polyester powder coat single. The driver unit must be accessible and if need be replaceable easily and with minimum use of tools.

b)

The casing made of non-corrosive aluminum having high conductivity shall have external surface designed in a manner so as to act as an efficient heat sink to extract heat generated at PN-junction of a LED. Efforts shall be made to install the fittings on the required street light pole without compromising on the performance of the LEDs or luminary.

c)

The assembly and manufacturing process for the LED source assembly in modules/arrays shall be designed to assure all internal components are adequately supported to withstand sudden impacts and mechanical shock and vibration from high winds and other sources.

d)

No part shall be constructed of polycarbonate unless it is UV stabilized.

e)

Material used for the lens of LED source shall be of toughened glass, heat resistant and shall not undergo discoloration during lifetime of the LED source. It shall conform to ASTM specifications for the materials. Any discoloration observed in the lens shall be considered a failure under warranty clause.

The fixture shall be designed in such a manner that it is easy to handle and install, is not too large and unwieldy, is of robust construction, light weight and conforms to minimum IP66 class of protection for outdoor use. 458

The luminary shall be provided with a built-in external heat sink as well as an aluminum MCPCB printed circuit board, designed in such a way that the heat generated within the LED source is efficiently dissipated to the surrounding atmosphere without abnormal rise in temperature. Any debris build up shall not degrade heat dissipation performance of the luminaries. A lighting luminaire fitted with an assisted cooling system is not acceptable.

m)

The Entire LED lamps should be driven by minimum 2 or more numbers of the driver circuits. The entire power supply to the LED Lamps should be divided among the drivers, thus each driver controlling a group of LED lamps.

7.10.5 Thermal Management

a)

The manufacturers shall ensure that the fixture is designed in such a manner that it conducts the heat away from the LEDs as efficiently as possible. The design shall ensure that the junction temperature is kept as low as possible during operation. Thermal management shall be in such a way that Luminare shall have trouble free operations from -20 ºC to +50ºC. The following tests shall be done to determine efficient thermal Management.

b)

The Fixture manufacturer shall perform solder point temperature (Tsp) measurement and compute junction temperature (Tj). The manufacturer shall show the proof that the junction temperature shall not go beyond the LED manufacturer‟s maximum junction temperature for long term lumen maintenance (i.e., 85% of the original value of lumen output after 50000 hours of operation).

c)

The fixture manufacturer shall furnish proof that the LEDs that have been offered and used in the fixture have White Point stability data (6000 Hours) as per IESNA‟s LM80-08, done at high ambient temperature 85°C and solder point temperature of 85°C.

d)

The fixture manufacturer shall furnish proof that the LEDs that have been offered and used in the fixture have been tested to IEC 62471 for safety requirements.

7.10.6 Electrical

a)

The LED fitted lighting fittings shall operate at 50 Hz +/- 3 % Hz AC over a voltage Ranging from 140V to 280V with a power factor > 0.95 in a 3-wire distribution system. The total power consumption in the LED lighting fixture shall not exceed the total guaranteed power consumption including power consumption in the electronic circuit of the driver for that particular application over the entire voltage range given in clause.

b)

The fluctuations in line voltage shall have no visible effect on luminous intensity of the LED luminaries. The operating voltage of the luminaries shall be 230V. All parameters measured at this voltage shall stand valid for the entire operating voltage range of 140- 280V.

c)

Total harmonic distortion (THD) of current and voltage induced into the AC power supply by an LED lighting source shall not exceed 15% for current and 5% for voltage. Harmonic Generation shall be as per EN61000-3-2 and EN61000-3-3 / IEEE 519. 459

The output circuit shall have short circuit and open circuit protection inbuilt to the driver unit.

h)

The material used in the construction of driver printed boards; driver enclosure etc. shall be non-flammable and heat resistant. Also, all the PCBs in the system shall be coated to prevent any corrosion.

7.10.7 Testing

a)

Design Qualification Testing shall be performed by the manufacturer or an independent testing lab hired by the manufacturer on new LED module/ array designs and when a major change has been implemented on an existing design.

The Luminaire manufacturer must show proof that the LEDs they use have been tested and approved to IESNA‟s LM80-09. The manufacturer must be able to provide the test data set to establish the authenticity and genuineness of the LEDs.

Type Test shall be carried out to prove confirmation with the requirements of specification and general quality/ design features of the unit. In case of any change in Bill of Material or design of unit, complete type test shall be repeated. If any sample fails in any of the type tests, fresh samples shall be taken and tested. If any sample again fails in that test, the whole lot shall be rejected.

ii.

Acceptance Tests are carried out by an inspecting authority at the supplier‟s premises on sample taken from a lot for the purpose of acceptance of a lot. Acceptance tests shall not be carried out from particular size or lot on which type tests have already been conducted,

iii.

Routine Tests shall be performed by the manufacturer on each complete unit of the same type and the results shall be submitted to the inspecting agency, prior to offering the lot for acceptance test. The firm shall maintain the records with traceability.

iv.

Mock up Test. The successful bidder shall provide proposed LED lamp and luminaries on three consecutive poles as demonstration to prove the suitability of the fittings matching with the requirement in regards to lux level, 460

quality of illumination for professional, objective & impartial review jointly by the bidders team along with team of MSME Engineers. This shall be carried out within two weeks from the date of issue of work order and prior to submission of detail design package for approval. Sample size and criteria for conformity The luminaries shall be selected from the lot at random. In order to ensure randomness of selection, procedures given in IS 4905-1968 (Reaffirmed 2001) may be followed. Test Scheme: Sr.

Description of Test

No

Type

Accepta

Routine

Test

nce

Tests

Tests 1

Visual and Dimensional

Y

Y

Y

Y

Y

Y

check 2

Checking of documents of purchase of LED

3

Resistance to humidity

Y

-

-

4

Insulation resistance test

Y

Y

Y

5

HV test

Y

Y

Y

6

Over voltage protection

Y

-

-

7

Surge protection

Y

-

-

8

Reverse polarity

Y

Y

Y

9

Temperature rise

Y

Y

-

10

Lux measurement

Y

Y

-

11

Fire retardant

Y

-

-

12

Test for IP66 protection

Y

-

-

7.10.8 Marking i. The following information shall be distinctly and indelibly engraved

on

the housing:  Year of manufacture  Batch Number  Serial Number 461

  

Name of Manufacturer Rated Wattage and Voltage (Input) Markings like CE, CB ii. ISO Certification: The agency shall preferably possess the ISO certification for design, Manufacturing and supply of the complete Lighting Unit. 7.10.9 Guarantee Terms and Condition a) Warranty b) In addition to meeting the performance requirements for the minimum period of 60 months, the manufacturer shall provide a written warranty against defects in materials and workmanship for the modules/ arrays for a period of 60 months after acceptance of the modules/ arrays. Replacement modules shall be provided promptly after receipt of modules that have failed at no cost to the Employer. c) The bidder shall stand guarantee for full replacement of the luminary due to any failure in 5 years, from the date of purchase. Failures shall include failure/ deterioration of LEDs in terms of performance like guaranteed luminous efficiency, high junction temperature, and abnormal lamp lumen depreciation, deterioration in LED including its lens, driver unit and quality of light. The vendor shall replace the entire LED module/ array of the defective luminaire with new module /array free of cost immediately. d) In the event of single LED source getting defective, the entire array/ module shall be replaced by the bidder by the new fittings. e) The bidder shall stand guarantee against lumen depreciation beyond 15%. Vendor shall ensure that LED module/ array shall deliver at least 85% of initial lumens, when installed for a minimum of 50,000 hours, failing which bidder shall carry out necessary rectification free of cost to the entire satisfaction of MSME. f) The bidder shall maintain appropriate level of inventory in India for immediate replacement of a defective/ malfunctioning luminary/ LED module/ array/ driver etc. 7.10.10 Compliance to Standards a) The luminaries shall comply with IS 10322 for functional, photometric and safety requirements. The fixture shall conform to safety standard EN60598. b) The luminaries shall conform to norms on transient voltages, voltage dips and fluctuations as per EN 61547. c) The luminaries fitted with LED source shall be CE and ISO certified to ensure quality of the LED source. d) The other relevant standards applicable to LED based lighting solutions to which lighting luminary must conform are as under: ANSIC78.377.2008

Specifications for the Chromaticity of Solid State Lighting Products

IESNA LM- 79-08

IESNA Approved Method for the Electrical and Photometric Measurements of Solid State Lighting Products.

Fluorescent Luminaries  These luminaries shall be generally indoor type provided with cold rolled cold annealed (CRCA) sheet steel channel / rail cum reflector housing complete with all electrical control accessories mounted onit. The finish shall be stove enameled.  Decorative fluorescent type luminaries shall be either open type, provided with translucent white opal acrylic diffusers, polystyrene lens prismatic or square polystyrene louvres.  Luminaries shall be suitable for the number of lamps of specified wattage, direct mounting on ceiling / wall/ column pendant mounting or for recess mounting in false ceiling.  Decorative luminaries with mirror optic reflectors shall be made with reflectors with a high specular reflectivity (of more than 90%) and wideangle dispersion type. Where these luminaries are mounted in control rooms and computer rooms, special type of anti-glare mirror (CAT-2) system shall be provided to direct the light output in the desired direction. This is mainly to reduce reflection of the light source from computer screens.  Luminaries mounted recessed in false ceiling shall be with reflector housing and spring loaded fixing arrangement for the diffuser / louvre frame. It shall be possible to have access to the lamp and other accessories from below.

 This luminaries shall be with cast aluminum base with LED lamp, red prismatic glass/acrylic cover, neoprene gaskets and bottom conduit / pipe entry.  The means for attaching the luminaries shall be designed to suit the weight of the luminaries and strength to withstand wind speeds as applicable to particular area as per relevant IS specification.  Environmental Lighting Luminaries d)

Reflectors  The reflectors shall be made of CRCA sheet steel / aluminium / silvered glass/ chromium plated sheet copper as indicated for above mentioned Luminariess.  Thickness of steel / aluminium shall comply with relevant standards specified in Data Sheet. Reflectors made of steel shall have stove enamelled / vitreous enamelled / epoxy coating finish. Aluminium used for reflectors shall be anodized / epoxy stove enamelled / mirror polished. The finish for the reflector shall be as indicated for above-mentioned fittings and or in Data Sheet.  Reflectors shall be readily removable from the housing for cleaning and maintenance without disturbing the lamps and without the use of tools. They shall be securely fixed to the housing by means of positive fastening device of captive type.

b)

Lamp / Starter Holders Lamp holders shall comply with relevant standards specified in Data Sheet. They shall have low contact resistance, shall be resistant to wear and shall be suitable for operation at the specified temperature without deterioration in insulation value. They shall hold the lamps in position under normal condition of shock and vibration met with under normal installation and use.

c)

Ballasts  Ballasts shall be designed manufactured and supplied in accordance with the relevant standards specified in Data Sheet. The ballasts shall be designed to have a long service life and low power loss.  Ballasts shall be of the inductive, heavy-duty type copper wire wound, filled with thermosetting, insulating, moisture repellent polyester compound filled under pressure or vacuum. Ballasts shall be provided with taps to set the voltage within the range specified in enclosed Data Sheet. End connections and taps shall be brought out to a suitable terminal block rigidly fixed to the ballast enclosure. Ballasts shall be free from hum and 465

such of those which produce hum shall be replaced by VENDOR with free of cost.  Separate ballast for each lamp shall be provided in case of multi lamp Luminaries, except in the case of 2 x 20 watts Luminaries. d)

Electronic Ballast Electronic ballast shall be suitable for 1x18W, 1x24W, 1x28W and 2x18W fluorescent lamp and shall be energy saving, warm start type having a power factor better than 0.96, having an optimum wattage delivery to the lamp. The choke shall be suitable for 180 – 270 V AC for operation at ambient temperature range of -15ºC to +50ºC. The choke shall have low radiated and conducted EMI / RFI. Refer BOQ

e)

Digital Ballast Digital ballasts shall be designed and manufactured with latest techniques using specially designed high-grade electronic components housed in pre coated galvanized sheet. Shall be suitable for operation with luminaries incorporating fluorescent and compact fluorescent lamps with dimming. The ballast shall be suitable for 200 – 320 V AC for operation at ambient temperature range of -15ºC to +50ºC. The ballast shall have low radiated and conducted EMI / RFI. Refer BOQ

f)

HIGH FREQUENCY ELECTRONIC BALLAST High frequency electronic ballast shall be used with fluorescent / Compact Fluorescent Lamps wherever specified in the schedule of quantities. High frequency electronic ballast shall comply to the following: 

IEC 927, IEC 928 for ≤10% total harmonic distortion.



EMI / RFI – Confirming to FCC / VDE Class A/B.



Line Transient as per IEEE C62.41.



Ballast Crest Factor C1.7%.



No Stroboscopic Effect



Constant Wattage / Light output between 240 V ± 10%.



Circuit protection for surge current and inrush current.



Short circuits, open lamp protection



PF > 0.99 for fluorescent / T5 lamp and 0.95 for CFL.



Deactivated lamp protection



Suitable for use with single and twin lamps



RFI < 30 MHz



Total Harmonic Distortion (THD)

≤10%



Immunity to interference

EN 61547



Safety

EN 60928 / IS 13021 (Part I)



Performance

EN 60929 / IS 13021 (Part II)



Vibrations & Bump tests



IEC 9001

EN 55015

IEC 68-2-6 FC

466

g)



Quality Standard

ISO 9001



Environmental Standard

ISO 14001



DC Operation



Emergency Lighting Operation

EN 60924 VDE 0108

Starters Starters, if required shall have bimetal electrodes and high mechanical strength. Starters shall be replaceable without disturbing the reflector or lamps and without the use of any tool. Starters shall have brass contacts and radio interference capacitors. The starters shall generally conform to the relevant standards specified in Data Sheet.

h)

Capacitors Capacitors shall have a constant value of capacitance and shall be connected across the supply of individual lamp circuits. Capacitors shall be suitable for operation at supply voltage and shall have a value of capacitance so as to correct the power factor of its corresponding lamp circuit to the extent of 0.95 lag or better. Capacitors shall be hermetically sealed preferably in a metal enclosure to prevent seepage of impregnant and ingress of moisture.

i)

Lamps 5 Star Rating Lamps shall be capable of withstanding small vibrations and the connections at lead in wires and filaments / electrodes shall not break under such circumstances. Lamps / tubes shall conform to relevant standards specified in Data Sheet.

High Intensity Discharge Lamps These lamps include the high-pressure sodium vapour lamp, metal halide lamps. High pressure sodium vapour lamps shall be with polycrystalline translucent, coated discharge tube, coated shell, quick restrike time (of within 5 minutes) and with burning life (about 10,000 hours) in standard ratings upto 400 watts. Metal halide lamps shall be single ended or double ended as required. The lamps shall be with quartz discharge tube and transparent / internal coated shell, quick restrike time (of within 5 minutes) with burning life (upto 5000 hours) in standard ratings upto 2000 W. The colour rendering index of these lamps shall be very high. These lamps shall be used only in enclosed Luminariess (lamps without protective coating) and can be used only in open Luminariess in lamps with Teflon or other coating to hold the shell in case of non-passive end of lamp life.

7.10.15 Lighting System Equipment

Light Control Switches a)

Light control switches of ratings and types, i.e. decorative/industrial, shall be supplied as indicated in project layout drawings/price schedule. The switches shall be suitable for use on 240 V, 1 phase, 50 Hz supply.

b)

Switches shall be of flush type for mounting behind an insulated plate or incorporated with a switch or switch box/suitable enclosure. The switch box/ enclosure may be recessed into or mounted on wall as per the requirements of project layouts.

c)

Size of enclosure boxes shall be chosen to accommodate the number of switches to be installed at the particular location. The enclosures shall be made of 1.2 mm thick CRCA sheet steel, stove enameled/galvanized. The enclosure box shall be covered with perspex/insulating cover. An enclosure intended for surface mounting shall not have holes or gaps in its sides other than those expressly provided for cable entry.

d)

Switches shall conform to the relevant standards.

7.10.16 Receptacle Units

a)

Receptacle units shall consist of socket outlet with associated switch, neon indicating lamp and plug. The socket outlet and switch shall be flush mounted within a stove enameled/ galvanized 1.2 mm thick CRCA sheet steel enclosure with perspex/insulating cover. The box may be recessed into or mounted on a wall as per requirements of project layouts.

Single-phase receptacles shall be associated with a switch/MCB of same current rating and the receptacle shall become live only when the associated switch/MCB is in “ON” position.

e)

Three phase receptacles shall be associated with a TPN switch housed in the same enclosure. The receptacle shall become live only when the associated switch is in “ON” position and it shall not be possible to withdraw the plug with the switch in “ON” position.

f)

Plugs shall be provided with cord grips to prevent strain and damage to conductors/wires at connection and entry points.

g)

Types and current ratings of receptacle units shall be as indicated in the layout drawing/price schedule and they shall conform to the applicable standards.

h)

Whenever stated in layout drawing/price schedule, receptacle units may be provided with MCBs instead of switch.

The installation of lighting fixtures shall be based on the mounting arrangement shown in the drawings enclosed with this specification. The unit rates quoted for installation shall include all materials required to mount the fixtures in the manner as shown in the drawings. Unit rate for installation of lighting fixtures shall include cost of installation of control gearbox wherever applicable.

b)

Installation of receptacles and switches shall be carried out suitably as per the lighting layout drawings. Switch shall be mounted in flush with the front cover plate. Cost of supply and installation of necessary hardware shall be included in the unit rates quoted for installation of receptacles/switches.

c)

Lighting distribution boards shall be installed in the location indicated in the layout drawings. Installation rates quoted for installation of lighting distribution boards shall include supply and installation of wall brackets, etc.

Description of top bracket / arms Single double decorative arm shall be provided on the pole (as asked for in B.O.Q.), secured with the help of two nos. bolts outreach not less than 400 mm.

c)

Service window A service window of the size 150 mm x 100 mm shall be provided in the base of the pole to allow access to electrical connections and terminations. It shall be covered with MS plate and proper rubber gaskets shall be provided to prevent any ingress of water etc.

d)

Electrical connections Four way connectors shall be provided along with Slide lock and 1 no. 6 amps Sp MCB including 2.5 sq mm PVC insulated copper conductor wires from the terminal block to the fixture and 2 nos. 32 mm dia GI sleeves of suitable length shall be provided up to the service window. An earth boss is provided on the control plate along with connectors and interrupters.

7.11 EARTHING SYSTEM 7.11.1 A complete earthing system comprising earthing conductors, earth electrodes and earth connections necessary for effective and permanent bonding to earth, all noncurrent carrying metal work and for termination of the earthing conductors of all electrical 415V switchboards, sub boards, distribution boards, etc., installed for the Electricity Distribution System for this project shall be supplied, erected and connected under this section of the specification and the associated drawings. Earthing conductor shall be as follows Conductors above ground level

Earthing main conductor shall be provided around the buildings and interconnected as shown in the drawings. The Main Conductor and tap off Conductors length buried in soil shall be wrapped with bitumen tape for protection against corrosion. Layout of earthing conductor inside the building shall be planned to provide earthing connection to all equipment and structures by short and direct earth leads. Grid riser in electrical shafts with tap-offs at each floor shall be provided. The joints in the run of the earthing conductors shall be welded type. Connections with equipment/ structure shall be of bolted type. Cable trays, steel pipes / conduits, steel columns, etc., shall not be used as earth continuity conductors. Earth connections for all sections of installation shall be electrically and mechanically sound. All electrical equipment rated 240 Volts and above shall be earthed at two points except the 3-phase / 1 phase receptacles, cable trays, lighting fixtures, conduits, hand rails, metallic non-current carrying structures, which shall be earthed at one point. All works performed under this section shall also comply with the requirements of the local authority, IS 3043, 1987 and Earthing and Lightning Protection SystemNotes and Details. All three phase equipment shall be double earthed. 7.11.2 Earthing Systems – Installation Notes General a)

These notes shall be read and considered in conjunction with earthing drawings and specification. In case of any conflict between these notes and drawings/ specification, the later shall prevail.

b)

Earthing system layouts are diagrammatic only. Exact location of earthing conductors, earth electrodes and test pits and connection may be changed to suit the site conditions. Major modification should be referred to EMPLOYER for clearance. 471

c)

Neutral point of the system of the different voltages, metallic enclosures and frameworks associated with all current carrying equipment and extraneous metal works associated with electric system shall be connected to a single earthing system unless stipulated otherwise.

d)

Earthing system installation shall be in strict accordance with the latest editions of Indian Electricity Rules, Relevant Indian Standards and codes of practice and Regulations existing in the locality where the system is installed.

Earthing conductor around the building shall be buried in earth minimum distance of 1500mm fro the outer boundary of the building.

d)

Earthing conductors embedded in the concrete floor of the building shall have at least 50mm concrete cover.

e)

Earthing conductor along their run on the columns, walls, etc., shall be fixed by suitable welding or cleating at intervals of 1000mm and 750mm respectively.

f)

Tap connections from the floor earthing grid to the equipment / structure to be earthed shall be terminated on the earthing terminals of the equipment, if the equipment is available at the time of laying the grid. Otherwise “earth raiser “ or “earthing pads” shall be provided near the equipment foundation / pedestal for future connection to the equipment earthing terminals.

g)

In outdoor areas, buried conductors shall be brought 500mm above the ground level for making tap connections to the equipment (above ground level)

h)

Earthing conductors crossing the road shall be either installed in Hume pipes are laid at greater depths to suit the site conditions.

Wherever earthing conductor passes through walls, floors etc., galvanized conduit / HDPE pipe sleeves shall be provided for the passage of the conductor. Both ends of the sleeve shall be sealed to prevent the passage of water through the sleeves. The seals in addition shall be fire proof if the specification / project drawings call for the same.

k)

Water stops shall be provided wherever earthing conductors enters the building from outside, below the ground level.

l)

Separate / isolated earthing system, if required, shall be provided for instrumentation and control and control systems in the plant, including dedicated earth pits.

7.11.4 Equipment And Structure Earthing

472

a)

Earthing pads / terminals will be provided by the manufacturer of the apparatus/ equipment at accessible positions. The connection between the earthing pads/ terminals and earthing grids shall be made by short and direct earthing leads free from kinks and splices.

b)

Whether specifically shown in drawing or not, Steel / RCC columns, metallic stairs, Hand rails etc., of the building housing electrical equipment shall be connected to the nearest earthing grid conductor by at least one earthing lead. Electrical continuity shall be assured by bonding the different sections of the handrails and metallic stairs.

c)

Electrical conduits, pipes and cable tray sections shall be bonded to ensure electrical continuity and connected to earthing conductors at regular intervals. Apart from intermediate connections end and beginning points shall also be connected to earthing system. These details are covered separately under cabling installation notes and details which shall apply.

A separate earthing conductor shall be provided for earthing lighting fixtures, receptacles, switches, junction boxes, lighting conduits, poles etc. This conductor in turn shall be connected to the main earth. These details are covered separately under lighting installation notes and details, which shall apply.

f)

Whenever earthing conductor crosses or runs at less than 300mm distance along metallic structures such as gas, water, steam pipes, conduits etc., and steel reinforcement in concrete, it shall be bonded to the same. In case earthing connection to pipe and conduit etc. at a distance higher than 300mm is required, the same shall be marked on the drawing.

g)

Miscellaneous items such as junction boxes, field switches, cable end boxes/ glands, fitting and fixture shall be earthed whether specifically show or not.

h)

In general minimum two earth leads shall be used for earthing each equipment / structure enclosing the power conductor operating at more than 250V and one earth lead if the voltage level is 250V or less.

7.11.5 Jointing a)

Earthing connections to equipment earthing pads / terminals shall be bolted type with GI bolts and nuts. Contact surfaces shall be free from scale, paint, enamel, grease, rust or dirt. Two bolts (min.) shall be provided for making each connection. Equipment bolted connections, after being checked and tested, shall be painted with anti corrosive paint/ compound.

b)

Connection between equipment earthing lead and main earthing conductors and between main earthing conductors shall be welded / brazed type. For rust protection the welds shall be treated with red lead and afterwards thickly coated with bitumen compound to prevent corrosion.

c)

Steel to copper, copper to copper connections should be brazed type. Welding shall be adopted in case of steel. Welding to be done as per IS: 816.

d)

The jointing whether welded, brazed of bolted shall be such that the resistance of the joint is not more than the resistance of the equivalent length of the conductor. 473

e)

Welding / brazing surfaces shall be cleaned and made free of all oxide films, grease, oil or any foreign material. However, the joining surfaces should not be made too smooth / highly polished, to prevent the joining material from flowing away.

f)

All brazing should be done by oxy- acetylene torch flame.

g)

All welded connections shall be made by electric arc welding. All welded joints shall be allowed to cool down gradually to atmospheric temperature before putting any load on it. Artificial cooling shall not be allowed.

All arc welding with large diameter conductor shall be done with low hydrogen content electrodes.

j)

For brazing alloys of silicon bronze/ phosphor or copper/ phosphor-silvercopper shall be used.

7.11.6 Cable Earthing Metallic sheaths, screens and armour of all multicore power/ control cables shall be earthed at both equipment and source / switchgear end. Sheath and armour of single core power cables shall be earthed at source /switchgear end only, unless otherwise stated elsewhere. 7.11.7 Testing & Commissioning After completion of erection works before equipment is charged, the following minimum test shall be carried out. All test shall be recorded in the format as approved by Architect/Project Manager besides the test mentioned below any other tests specified by the local authority shall also be carried out. All tools and celebrated instruments for testing, labour, materials and incidentals necessary, to conduct the tests mentioned below shall be provided by the contractor at his own cost. 

Insulation resistance test of all the feeders by 500 V megger.



Insulation resistance test of all LT cables with 500 V megger.



Continuity test of all the cores and the armour cables.



Sheathing continuity test.



Testing of Wiring:



All wiring systems shall be tested for continuity of circuits, short and earthing after wiring is completed and before installation is



Testing of Earth Continuity Path:



Insulation resistance Test



Polarity test of switches

circuits, energized.

The above test reports shall be submitted by contractor to Engineer incharge.

conductors shall be fixed in such a way that they remain in their installed position even during severe weather conditions. The necessary accessories such as cleats, clamps, welding materials, bolts, nuts, shall be supplied by CONTRACTOR. 7.12.2 Air termination system shall be connected to earthing system below ground by down conductors as shown in various project drawings. For this purpose separate treated earth pit to be constructed. The down conductors shall follow a direct path to earth. There shall not be any sharp bends, turns and kinks in the down conductors. 7.12.3 All joints in the down conductors shall be of welded/brazed type. All metallic structures within 2 meters from down conductors shall be bonded to lightning protection system. 7.12.4 The lightning protection system shall not be in direct contact with underground metallic service ducts, cables, cable conduits and metal enclosures of electrical equipment. However all metal projections, railings, vents, tanks etc. above the roof shall be bonded together to form a part of roof grid.

7.13 DIESEL GENERATORS 7.13.1 Scope

The scope of this section consists of but not necessarily limited to the following in accordance to Technical specification prescribed in tender: a)

The contractor shall supply, deliver to site, hoisting into position, install, test and commission the Prime rated power generating set together with the necessary controls and switchboards as specified and indicated in the Drawings. Protection circuits, control wiring and interlock circuits not specified or indicated in the Drawings, but deemed necessary for the safe operation of the generating system shall be provided without any additional cost to complete the system. b) Provide manufacturer‟s factory representative‟s services, including coordination, and start-up and testing supervision. c) Testing (factory and field), start-up supervision, training and providing necessary documentation and tools for operation. d) Carry out performance test run at site with Load bank & Lube oil etc. arranged by contractor. 7.13.2 Engine Engine shall be multiple cylinder vertical, 4 stroke cycle, Prime rated, multicylinder direct injection, compression ignition type operating at a speed of 1500 rpm and shall be silent, vibration free while in operation and comply Center / State Pollution Control Board , turbo charged after cooled as BS 5514/ISO 3046, 1500 RPM. Engine shall deliver not less than 400kW at site at 0.8 lagging power factor and shall be suitable for sustaining of 10% overload for 1 hour in every 12 hours of continuous operation at full load without damage. Engine shall be with the following accessories: a)

2 No. 12 volt 25 plate lead acid batteries in series and parallel connection to make 24 volts, 4 x 180 Ah batteries duly charged along with connecting leads mounted on acid resistant frame work. Anti vibration mounts as per manufacturer recommendation. Electronic Governor with governing class „A‟ direct. All moving parts to be mechanically guarded to minimize hazard to people around. Air intake and exhaust systems with filters, residential type silencers, ducts, pipes, dampers, fittings, supports and other necessary accessories. The exhaust gas expulsion system shall be in accordance with the drawings. The exhaust piping shall be fitted with hospital type silencer in order to limit the sound level. Expansion joints shall take care of thermal deformations. The pressure drop in exhaust piping including silencer, bends, expansion joints etc., shall be compatible with exhaust gas leaving the engine. The exhaust piping shall be duly covered throughout the length from engine outlet upto the outlet point with mineral wool insulation and aluminium sheet cladding. The exhaust piping shall be independent for each engine and shall be with minimum bends. The bending radius of bends shall be not less than 3-internal diameters of 476

chosen piping. A drain plug shall be fitted at the lowest point of piping for condensate extraction. The exhaust pipe shall meet the following regulations of pollution board as mentioned. Suitable supports shall be provided for proper installation of exhaust pipes. 7.13.3 Limits Of Noise For Power Generating Sets Manufactured On Or After The 1st

January, 2005

7.13.3.3Applicability

These rules apply to Generator sets of rated output, installed on or after 1st January, 2005. 7.13.3.4Requirement of Certification

Every manufacturer or importer of Power Generating set must have valid certificates of Type Approval and also valid certificates of conformity of production for each year, for all the product models being manufactured or imported after 1st January, 2005 with the specified noise limit. All Power Generator shall have a valid Type Approval certificate and conformity of production certificate. All Power Generator shall have conformance label meeting the requirements. The conformance label shall contain the following information: a)

Name and address of the supplier (if the address is described in the Client‟s manual, it may not be included in the label).

The following agencies are authorized to carry out such tests as they deem necessary for giving certificates for Type Approval and Conformity of production testing of Generator and to give such certificates : a)

Automotive Research Association of India, Pune.

b)

National Physical Laboratory, New Delhi.

c)

Naval Science & Technology Laboratory, Palghat

d)

National Acrospace Laboratory, Bangalore 477

7.13.3.6Alternator

The alternator shall be brushless synchronous and suitable for 3 phase, 415 volts, 50 Hz., 0.8 p.f. and 1500 RPM. The alternator shall be suitable for coupling directly to the engine described in clause no. 1.3 It shall be drip proof screen protected as per IP23. The alternator shall be continuously rated and shall have class “H” insulation designed and built to withstand tropical conditions. It shall be confirming to IS:47221992. The output of the alternator shall be 400 KW rated output at site conditions at 0.8 lagging power factor and shall be suitable for sustaining of 10% overload for 1 hour in any 12 hours period without damage. Six nos. embedded Resistant Temperature Detector (RTDs) of plantinum, 100 ohms resistance at 0 degree to measure the winding temperature and 2 Nos. BTDS to measure bearing temperature shall be provided. The leads of embedded RTDs shall be wired upto the terminal block in a separate terminal box. Manufacturer shall indicate the setting values for each RTD/ BTD for alarm and trip. Greasing facility with grease nipples and grease relief device shall be provided. All external nuts and bolts shall be of high tensile steel only. Alternator shall be provided with anti-condensation space heater of adequate rating suitable for 240 V, 50 Hz, 1 Phase AC supply and shall be wired upto a separate terminal box. The independent earth terminals on the frame complete with nuts, spring washer and plain washer shall be provided. Alternator shall be provided with suitable adaptor box for termination of cables. Suitable arrangement shall be provided in the terminal box for formation of star point for Alternator neutral earthing. QDCT for synchronizing relay i.e. DG Set shall be capable of working in synchronizing with other DG sets. The supply of any relays, contactors, CT‟s etc required for this purpose shall be included. Alternator shall be suitable for bearing the starting current of Transformer after changeover. 7.13.3.7Excitation System

The alternator shall be provided with a complete rotating diode type brushless excitation system, capable of supplying the excitation current of the generator under all conditions of output from no load to full load and capable of maintaining voltage of the generator constant at one particular value. The exciter shall have class „H‟ insulation. The excitation system shall comprise a shaft driven AC exciter with rotating rectifiers. The rectifiers shall have in-built protection for over voltage. The exciter shall be fast response type and shall be designed to have a low time constant to minimize voltage transients under severe load changes. The excitation voltage response ratio shall be at least 0.8. The rated current of the main exciter shall be at least 10% more than the alternator rated exciter current and it shall have 40% overload capability for 10 seconds. 478

No external supply shall be required during starting and normal running of the alternator. 7.13.3.8Automatic Voltage Regulator

An automatic high speed, dead band type voltage regulator shall be provided, complete with all accessories. The regulation system shall be provided with equipment for automatic and manual control. The regulator shall regulate the output voltage from generator current and potential signals. Series compounding transformer shall be provided to enable maintaining adequate terminal voltage in the event of terminal faults. Alternatively excitation system shall be provided with arrangement for field forcing. Contractor shall coordinate suitability of protection relays for generator with the operational characteristics of automatic voltage regulator, specially under short circuit conditions. Voltage regulation and steady state modulation shall be within +/- 0.5% of the line voltage. Necessary equipment for field suppression and surge protection shall be provided as integral part of alternator. The response time of exciter and the generator shall be properly matched to avoid hunting. AVR system shall be provided with equipment for automatic and remote operation / control. AVR shall be suitable for 24 V supply. Necessary equipment shall be furnished for the following. 

To prevent automatic rise of field voltage in case of failure of potential supply.

General The auto synchronizing shall be provided as mentioned below and as per Schedule of Quantity. Protection Through Relays (For DG Set) Following protection shall be provided through Numerical relay both for the stator side and the rotor side if not provided in the controller: a) Voltage restrained over current protection (50/51) Relay shall not work when a over current fault occurs, due to higher current levels. There shall be drop in terminal voltage for the same fault impedance, the fault current shall reduce (with respect to terminal voltage) to a level below the pick-up setting. Consequently, relay shall not pick-up. It shall be necessary to have a relay whose pick-up setting shall be automatically reduce in proportion to terminal voltage. Hence, the over current protection shall be voltage restrained. Two levels over current protection shall be provided i.e. low set and high set (for short circuit protection) b) Thermal overload (49) It monitors the thermal status of machine for current between 105% to the low set O/C level (normally 150%). c) Under / Over Voltage (27 / 59) This will protect the machine from abnormal voltage levels, particularly during synchronization and load throw off conditions. d) Under / Over Frequency (81)

480

This will protect the machine from abnormal frequency levels, particularly during synchronization and load throw of conditions. This will also help in load shedding scheme for the generator. e) Breaker Failure Protection (52 BF) This protection detects the failure of breaker to open after receipt of trip signal. Another trip contact is generated under breaker fail conditions, with which more drastic measures (like engine stoppage, etc.) can be taken. 7.13.3.11 Metering For Each DG

All standards checks including the ones elaborated in the specifications to ensure that the installation of the DG sets and associated systems has been carried out satisfactorily shall be done on completion of installation. These shall include. DG sets a) b) c) d) e) f) g)

Checking of piping interconnections Checking electrical interconnections Checking of insulation resistance Checking of earthing Checking of instruments and controls. Checking of alignment Checking of vibration transmission to building a structure. 481

h)

Checking of expansion joints. Exhaust system

a) b)

Checking of silencer operation Checking of surface temperature of exhaust piping Fuel system

a)

Checking of automatic operation of fuel transfer pumps. Upon completion of work the performance test shall demonstrate the following among other things:

a)

Equipment installed complies with specification in all respects and is of the correct rating for the duty and site conditions.

b)

All items operate efficiently and quietly to meet the specified requirements.

c)

All circuits are correctly protected and protective devices are properly coordinated.

d)

All non current carrying metal parts are properly and safely grounded in accordance with the specifications and appropriate codes of practice.

7.13.3.14 DG Sets – Test Procedure

The Tenderer shall enclose copies of type test certificates, wherever applicable, for all the equipments and materials, quoted by him, along with the bid for Employer‟s reference as per the relevant standards specified. All the type tests, if not conducted earlier on similar type of equipments, covered under the relevant standards, shall be conducted, wherever required, by the suppliers for all the equipment and materials at manufacturer‟s works in the presence of the Employer‟s representative. The test certificates of all the equipments / materials shall be approved by the Employer‟s representative before dispatch / acceptance of the equipment and materials. Routine tests for all equipment will be witnessed by Engineer‟s Representative. The following tests shall be done at works before dispatch, Tests on alternator: 1

The following tests shall be carried out on Generator and Excitation system: a)

Insulation Resistance Tests

b)

Winding Resistance Test

c)

Phase sequence Test

d)

Open and Short Circuit Characteristic Test

e)

AVR response / Regulation Test.

f)

Load test on Generator at both unity and 0.8 PF.

g)

Excitation at full load and under specified variation of voltage and speed 483

h)

Measurement of voltage dips at the generator terminals while feeding the base load 75% and on simultaneous starting of the largest motor.

i)

EMPLOYER reserves the right to reject the equipment if the guaranteed performance is not met with.

j)

All instruments required for performance testing of the equipment covered in this specification shall be provided by the TENDERER at no extra cost to the Employer for entire duration of the performance test.

k)

The TENDERER shall ensure that instruments and gauges to be used for testing and inspection of critical parameters as identified in the specification shall have valid calibration and the accuracy can be traceable to National Standards.

l)

In addition to the above guarantees, TENDERER shall also guarantee the period for completing supply, erection, testing and commissioning as six (6) months for DG set and accessories from the date of Letter of Award.

Load / Run Test at Site : DG sets shall be tested at different loads at site after dispatch and installation at site. In case at any point of the test a trip should occur the test shall be conducted again. The necessary fuel oil, lube oil & consumables required for the test shall be provided by contractor. No extra payment shall be made in this regard. Copies of manufacturer‟s type test for the engine and the alternator of all ratings shall be enclosed along with the dispatch of the DG sets as per relevant standard/ codes. The contractor shall provide all necessary instruments and labour for testing. He shall make adequate records of test procedures and readings and shall repeat any tests requested by the Engineer Incharge. Test certificate duly signed by an authorized person shall be submitted for scrutiny. If it is proved that the installation or part thereof is not satisfactorily carried out then the contractor shall be liable for the rectification and retesting of the same as called for by the Engineer Incharge. All tests shall be carried out in the presence of Client inspection team.

484

These tests shall form part of this contract. Above tests shall be conducted for all DG sets. The test results shall match with the technical requirements specified in the technical data sheet. The Engineer Incharge shall have the right to accept or reject the modules if it does not meet the technical requirements. The load test shall be conducted through resistive load bank at unity power factor. Before conducting test, following shall be recorded on test report : a)

Engine serial No.

b)

Engine model & make No.

c)

Alternator serial No.

d)

Engine & alternator rating

e)

Date of testing

f)

Rated speed, voltage & kW

Loads & duration: Engine shall be given a test run for atleast six hours with alternator supplying full rated load at site and overload test to the extent of 10% over the rated load shall be conducted immediately after the full load run test No load : 5 mins 25% load – 30 mins 50% load – 30mins 75% Load – 30 mins 100% Load- 4.5 hrs 110% Load – 1 hr The following parameters shall be noted on the test report Description

Time ( After start of Load test) 1 hr 2hrs 3hrs 4hrs 5hrs 6hrs 7hrs

a)

Load in kW

b)

Power factor

c)

Voltage

485

d)

Current

e)

Frequency

f)

Alternator winding temperature

g)

Alternator bearing temperature

h)

Lube oil pressure

i)

Lube oil temperature

j)

Fuel consumption though flow meter

k)

Cylinder head temperature

Impact test: A block load of at least 50% shall be put on the DG from no load condition & similarly when DG is 100% loaded, the load is removed & the parameters like voltage, frequency & RPM is noted. The readings should be with in acceptable limits. Performance Tests a)

The following items of performance shall be guaranteed during site performance tests in respect of the DG and the auxiliaries for the specified site conditions:

b)

Net electrical output (continuous)

c)

Freedom from vibration and noise

d)

Governor response, over-speed trip and speeder gear capability

e)

Voltage regulator response

f)

Excitation at full load and under specified variation of voltage and speed.

Start-up & testing at site A equipment manufacturer's representative approved by the Project Manager / Client shall be engaged to perform start-up and load test upon completion of installation with the Project Manager / Client in attendance. A certified test record shall be provided. Tests shall include, but are not be limited to, the following:

486

a)

Check fuel, lubricating oil, and antifreeze in liquid cooled models for conformity to the manufacturer's recommendations under environmental conditions present.

b)

Test, prior to cranking of engine, for proper operation of accessories that normally function while the set is in a standby mode.

Test by means of simulated power outage, automatic start-up by remoteautomatic starting, transfer of load, and automatic shutdown. Engine generator sets are to be synchronized and paralleled during tests. Monitor throughout the test, engine temperature, oil pressure, battery charge level, generator voltage, amperes, and frequency.

e)

Tests shall demonstrate capability and compliance of system with operating requirements. Where possible, correct malfunctioning units at site then retest to demonstrate compliance; otherwise remove and replace with new units, and proceed with retesting. Retesting to be at no cost to the Project Manager / Client.

f)

This section includes a very basic outline of the start-up sequence. The actual sequence will be determined after the final design is completed. The commissioning of the new generators will occur on weekends and after-hours depending upon the scheduling requirements of the business.

7.13.3.15 Rejection

The Employer may reject any DG Sets during tests or service any of the following conditions arise and the provision under the relevant clause of the general conditions of contract shall immediately become applicable: If it is not adhere to:a)

GUARANTEED TECHNICAL PARTICULARS- Diesel Engine.

b)

GUARANTEED TECHNICAL PARTICULARS- Generator

c)

DG Sets fails on performance guarantee test at works.

d)

DG Sets fails on performance guarantee test at site. 487

e)

Proven performance in number of running hours for the type / Model of the DG set

f)

DG Sets is proved to have been manufactured not in accordance with the agreed specification.

g)

The Employer reserves the right to retain the rejected DG Sets and take it into service until the tenderer replaces the defective DG Sets by a new acceptable DG Sets at no extra cost. The tenderer shall repair or replace the DG Sets within a reasonable period mutually agreed time to the satisfaction of the Employer at no extra cost.

7.14 UPS SYSTEM 7.14.1 General Requirements

a)

This specification covers the design, manufacture, testing, inspection at Manufacturer‟s works, packing, forwarding and transport to site, unloading, storing, installation, testing and commissioning of the UPS System as described herein and shown on the drawings. b) The UPS system shall consist of rectifier / battery charger, batteries, inverter, static bypass transfer switch, synchronizing devices, protective devices, bypass switch, filter circuits, and accessories as specified herein that will automatically maintain the continuity of electrical power within specified tolerance, without interruption, upon failure of the normal power supply. c) The UPS system shall be manufactured in a modular way so as to enable the power of the UPS system installed to be easily increased on the site by paralleling more than one module to meet the new operating requirements and the desired reliability. In this connection, transformation of unitary module into a multi-module configuration shall be able to be carried out directly on site without returning the equipment to the factory for modification and with a minimum installation down time. 7.14.2 Quality Assurance a) UPS ratings shall be the final effective values after the application of all appropriate derating factors. These ratings shall be adjusted to suit local conditions, viz. maximum ambient temperature, etc.. Derating factor due to the non-linearity of the load to be connected to the UPS shall be taken into account. b) The UPS shall be manufactured for continuous reliable operating such that the “Mean-Time-Between-Failures” (MTBF) for individual modules of the UPS viz. Rectifier / charger unit, inverter unit and static switch, etc.. shall be more than 8760 hours. c) To ensure minimum down time, the “Mean-Time-To-Repair (MTTR) of the UPS shall not exceed one (1) hour. The MTTR shall be the time required to diagnose the fault and restore the UPS to normal working condition, say by means of module replacement at site, but excluding the traveling time. d) All battery use shall be heavy duty type of life span of minimum 5 years. e) The factory acceptance test shall include the following as a minimum: 488

Submission All technical submissions shall be approved by the Engineer in charge / Architect. As a minimum requirement, the submission shall include the following: Shop drawings showing the co-ordinated installation detail diagram Client‟s works requirement; Battery arrangement and manufacturer confirmation on „zero‟ gas emission by battery to meet Civil Defence requirement without separate room ventilation requirement.

System Operation The UPS system shall generally include its basic and supporting equipment for the monitoring, control and protection of the system, including input the output AC filters, electronic AC line conditioner, AC and DC input and output circuit breakers, converter, invertor, shielded isolation transformer, static by-pass switch and mechanical bypass switch. The battery bank may be in a separate matching battery enclosure (s). 7.14.8 Under normal conditions, power from the mains shall be supplied to the rectifier / charger unit. The rectifier / charger unit shall convert the incoming AC power to DC power which is fed into the inverter unit and battery unit. The inverter unit shall convert the DC power to AC power, which is then supplied to the load through the static transfer switch. As long as the operable inverter unit is supplied with DC, it shall supply AC to the load. 7.14.9 Upon failure of the mains, the battery shall maintain the flow of DC to the inverter unit and the inverter unit shall continue to supply the load without interruption. Upon restoration of mains supply or when the generator supply is available, input power for the inverter unit and for the recharging of the batteries shall automatically be supplied from the rectifier / charger output without interruption. If the battery is exhausted before the availability of the mains or generator supply, the UPS system shall shut down automatically. 7.14.10 The static transfer switch shall normally connect the inverter output power to the load. Should the inverter malfunction, the static switch shall automatically transfer the load to the bypass source without interruption of the power supply to the load. 7.14.11 During periods when the UPS system is being serviced, the transfer switch shall be operated to transfer the load to the bypass source. 7.14.12 In the case of the parallel redundant system, the total system load shall be automatically distributed equally between the two UPS modules under normal conditions. Malfunction in one of the UPS modules shall cause instantaneous isolation of the faulty module from the system and the remaining healthy UPS module shall take over the full critical load without interruption. If both UPS modules fail, the critical load shall be transferred to the bypass source. 7.14.6 7.14.7

489

7.14.13 Functional Requirements

a)

b)

c)

d)

e) f) g) h)

i) j)

Contractor shall furnish On-Line Uninterruptible Power Supply (UPS) system of continuous duty of the ratings mentioned in Bill of Quantities. Each UPS shall give regulated filtered & uninterruptible power supply as described in the specifications. Contractor shall note that the KVA ratings of the UPS systems shall be guaranteed at 50 deg.C ambient temperature. In case contractor‟s standard UPS KVA rating are based at a lower temperature, the contractor must consider a derating factor of atleast 1.5% per deg.C for arriving at the specified UPS capacity at 40 deg.C ambient temperature. In case the calculated /specified UPS capacity is not the same as one of the standard KVA ratings of the UPS manufacturer, the next higher standard KVA rating shall be selected. UPS of non standard rating shall not be acceptable. UPS system supplied by the contractor shall be the latest state of the art technology system fully digitalized using microprocessor controlled full wave rectification and IGBT inverter. Batteries shall be valve regulated lead acid specially meant for UPS application. Monitoring and control system shall also be state of the art technology LCD touch panel type providing all relevant data described in this document. The monitoring and control system shall be capable of RS232 input software for connecting to customer‟s computer system for data display and monitoring. All necessary components required for protecting UPS equipment and connected inputs and outputs shall be furnished by the Contractor as an integral part of the UPS system. The control logic power supply shall have redundant power supply AC input and the system battery as power sources. The UPS systems shall include but not be limited to the following equipment :  UPS system including 100% capacity float-cum-boost charger with 100% sealed valve regulated lead acid batteries with guaranteed battery life of 5 years.  Suitable factory built battery cabinet for housing the batteries, including terminal isolator / breaker and power disconnect device. The enclosure shall conform to IP 20 as minimum.  All cables, connectors, accessories like turning, cable trays, conduits etc. required for connection between battery and the UPS unit.

7.14.14 Static Converter

General The static converter (rectifier) shall be a multi-functional converter providing functions of power conversion, battery charging and shall have the additional functions of input power factor improvement and current harmonics reduction by PWM / IGBT filter. The converter equipment shall include all necessary control circuitry and device to conform requirements like voltage regulation, current limiting, wave shaping, transient recovery, automatic synchronization etc. as given below. The converter shall be a solid state static PWM converter utilizing Intelligent Power Module (IPM) and shall include intelligent features like the drive circuitry, over

490

current protection, over temperature protection, control power failure protection and short circuit protection. The IPM transistors shall enable high speed switching at 6 KHz thus reducing the heat dissipation in the UPS and thereby providing high efficiency. The PWM converter shall utilize the above and achieve unity power factor and reduce input current harmonics as given earlier and thus improve the overall power factor of the converter achieving input KVA savings. During any step inverter load change (0-100%) the converter shall only supply 100% current to the inverter. The battery shall not be cycled at any time during this step load changes. a)

Input Current Limit

The converter logic shall provide input current limiting by limiting the DC output current. Two (2) line-side current transformers shall be employed as a means of sensing the current amplitude. The converter logic shall also be capable of providing auxiliary current limited when the logic is signaled to do so via an external dry contact closure (e.g. UPS fed from generator). The converter shall be capable of supplying overload current in excess to the full load rating. It shall also have sufficient capacity to provide power to a fully loaded inverter while simultaneously recharging the system battery to 95% of full capacity within 10 times the discharge time. The DC output current limit values shall be as follows: Rectifier output current (maximum) 100% battery recharging mode.

Note : 100% current shall be under the

Battery Charge Current Limited The converter logic shall provide current limiting function of battery charging to prevent the battery from damage. The following battery current limit and protection shall be provided. 

Battery charge current limit 10% of battery Ah rate.



Over-current protection at 120% of above item.

b)

Voltage Regulation

The rectifier / charger output voltage does not deviate by more than +/- 1% of the nominal output voltage, due to the following conditions: 

From 0 to 100% loading.



Rectifier input variations of voltage and frequency within the limitations set.



Environmental condition variations within the limitations set.

7.14.15 Automatic Input Current Walk-in

The converter logic shall employ circuitry to allow a delayed and timed ramping of input current. Subsequent to energizing the converter input, the ramping of current shall be delayed by a maximum of 3 seconds. Upon starting the walk-in process, the ramping of current is timed to assume the load gradually within 1 through 60 seconds (every 1 second selectable). 7.14.16 Input Overload Protection

The A/C input fuses shall be provided at the converter input as a means of overload protection.The AC maximum current shall be controlled by the Converter. 7.14.17 Equalizing Charge Timer 491

The UPS logic shall provide an electronic automatic equalize charge timer which shall be selectable 24 hours for Lead Acid type or 8 hour for Alkaline type batteries. The timer circuit, once activated shall provide a high rate equalizing charge voltage to the system battery for the selected time. The circuit shall also be capable of manual activation via the LCD touch panel mounted on the front door. The level of equalizing voltage shall be equal to that stated by the battery manufacturer. Upon completion of the timer count, the converter output voltage shall automatically return to the specified float voltage. 7.14.18 Step Load Change

During any step inverter load change (0-100%), only the converter shall supply 100% current to the inverter. The batteries SHALL NOT be cycled at any time during these step load changes. 7.14.19 Input Voltage

The converter shall be fed from the Normal Power Supply source. 7.14.20 The converter shall meet the above specifications in addition to other requirements

stated in Data Sheet. Static Inverter General The static inverter shall be of solid state type using proven Pulse Width Modulation (PWM) technique. The inverter equipment shall include all necessary control circuitry and devices to conform requirements like voltage regulation, current limiting, wave shaping, transient recovery, automatic synchronization etc. as given below. The inverter shall utilize Insulated Gate Bipolar Transistors (IGBT) or Intelligent Power Module (IPM) Transistors which shall provide intelligent features like the drive circuitry, over-current protection, over temperature protection, control power failure protection and short circuit protection. The IGBT / IPM transistors shall enable high speed switching of 6 Khz thus reducing the heat dissipation in the UPS and thereby providing high efficiency. The UPS shall utilize both Voltage and Current feedback control circuits so that the inverter shall act not only as a constant voltage source but also as a load required current source. This shall enable the inverter to quickly adapt to the changing load current value and wave shape. 7.14.21 Voltage Regulation

The inverter output voltage shall not deviate by more than +/- 1% RMS due to the following steady state conditions: a)

From 0 to 100% loading

b)

Inverter DC input voltage varies from maximum to minimum.

c)

Environmental conditions variations within the limitations.

7.14.22 Frequency Control

The inverter output frequency shall be controlled by an oscillator internal to the UPS module logic. It shall be capable of synchronizing to an external reference (e.g. the bypass source or another UPS module) or operating asynchronously. The oscillator shall maintain synchronization with the external reference within the limitations set hereunder. The inverter shall operate on self run mode without synchronism if the bypass frequency exceeds the set value. The oscillator, while running 492

asynchronously, shall maintain the frequency as 50 Hz + 0.01% (or + 0.005 Hz). Automatic adjustment of phase relationship between inverter output and standby bypass source shall be gradual at a controlled slew rate which shall be adjustable at the rate of 0.5, 1.0, 2.0, 3.0 Hz / second. (default 2.0 Hz / second). The inverter output frequency shall not vary during steady state or transient operation due to the following conditions: a)

From 0 to 100% loading.

b)

Inverter DC input varies from maximum to minimum.

c)

Environmental condition variations within the limitations.

7.14.23 Output Voltage Harmonic Distortion

The inverter output shall limit the amount of harmonic content to the values as indicated in data sheets. The use of excessive or additional filtering shall not be required to limit the harmonic content thus maintaining a high level of efficiency, reliability and original equipment footprint. 7.14.24 Output Overload Capability

The inverter output shall be capable of providing an overload current while maintaining rated output voltage to the values as indicated in data sheets. An LED indicator shall be located on the control panel to identify this condition. If the time limit associated with the overload condition expires or the overload is in excess of the set current amplitude, the load shall be transferred to the bypass source without interruption. 7.14.25 Inverter Current Limit

The inverter output shall be limited to 150% of rated load current. The two sensing locations shall operate separately and independently thus providing redundancy and, in the event of a failure, preventing unnecessary damage to power transistor components / fuses. Load current above 150% shall cause an immediate transfer of the load to the bypass source for fault clearing. 7.14.26 Inverter Overload Protection

The AC output from the inverter shall utilize fuses for overload protection. The inverter shall utilize a contactor to isolate the inverter output from the critical bus. The inverter fuses shall be the fast acting semiconductor type. The inverter output isolation contactor shall be located in the UPS module and shall be controlled by the internal UPS module system logic. The inverter shall meet the following specifications in addition to other requirements stated in Data Sheet. 7.14.27 Built-in Isolation Transformer

This shall provide neutral separation which shall mean that output neutral will be independent of incoming neutral, hence critical load shall be isolated from the problems like incoming neutral open or, short or, variations in neutral to earth voltage due to sudden loading in neighboring installation. 7.14.28 Reverse Phase Sequence Protection

In the event of Phase sequence reversal at the input, UPS system shall continue to work on the main power supply, or UPS systems shall go into battery mode, and shall not trip the UPS system. 493

7.14.29 The overall efficiency of complete UPS system shall not be less than or equal

to

94% 7.14.30 Bypass And Static Transfer Switch

A bypass circuit shall be provided as an alternate source of power other than the inverter. A high speed switch and wrap-around contactor shall be used for the critical load during automatic transfers to the bypass circuit. The static switch and wraparound contactor shall drive power from an upstream bypass feed circuit breaker internal to the UPS module provided for overload protection. The wrap-around contactor shall be electrically connected in parallel to the static switch and shall at the same time as the static switch, energize and upon closure, maintain the bypass source. The static switch shall only be utilized for the time needed to energize the wraparound contactor thus increasing reliability. The bypass circuit shall be capable of supplying the UPS rated load current and also provide fault clearing current. The UPS system logic shall employ sensing which shall cause the static switch to energize within 150 microseconds thus providing an uninterrupted transfer to the bypass source when any of the following limitations shall exceed: a)

Inverter output under voltage or over voltage.

b)

Overload beyond the capability of the inverter

c)

DC circuit under voltage or over voltage

d)

Final end voltage of system battery is reached.

e)

Bypass source present and available

f)

System failure (eg. Logic fail, fuse blown, etc.)

7.14.31 Keeping the above requirements in view, the static switch shall have the

following minimum rating. Capacity continuous equal to 100% of continuous rating of the inverter. Capacity overload equivalent to overload characteristics specified for UPS. Technical parameter are given in Technical Data sheet shall be followed.

7.14.32

Automatic Re-Transfer In the event that the critical load must be transferred to the bypass source due to an overload, the UPS system logic monitors the overload condition and, upon the overload being cleared, perform an automatic re-transfer back to the inverter output. The UPS system logic shall only allow a re-transfer to occur three times within a ten minute period. Re-transfer shall be inhibited on the fourth transfer due to the likelihood of a recurring problem at the UPS load distribution. The re-transfer a load to the inverter shall also be inhibited due to the limitations set.

7.14.33 Manual Transfer

The UPS shall be capable of transferring the critical load to / from the bypass source via LCD touch panel. When performing manual transfer to inverter or automatic retransfers, the UPS system logic shall force the inverter output voltage to match the bypass input voltage and then parallel the inverter and bypass source providing a make-before-break transition allowing a controlled walk-in of load current to the inverter. 7.14.34 Maintenance Bypass Switch (MBS)

The UPS shall include as standard equipment, a zero energy maintenance bypass switch. Full UPS wrap-around enables personnel to do work inside the UPS module or maintenance bypass switchboard without danger from high voltage conditions. 494

7.14.35 UPS Battery System

a)

The UPS system shall, as an integral part, provide battery system for 15 minutes (Full Load) standby capacity. b) The latest state of the art Valve Regulated Sealed Maintenance Free Lead Acid Batteries shall be used with a 20 hours discharge rating. c) The battery system shall be sized to provide 15 minutes back up time when the UPS is supplying 100% rated load at 0.8 load power factor. d) An ageing factor of 15% shall be applied to the capacity arrived at, to allow for compensation against capacity loss during float operation. e) The battery system design shall be provided with necessary devices to prevent deep discharge beyond recommended limits to prevent the batteries discharging beyond end cell voltage specified by the battery maker. The connections from battery to battery shall be by using copper bus bar strips and the entire battery system shall be used in IP20 steel cabinet enclosure and shall be similar to the UPS enclosure. f) All batteries shall be clearly identified and identification numbers marked on the batteries and a schematic diagram along with the complete calculations, including manufacturers supporting curves, shall be submitted with the tender. 7.14.36 Operation a) Under normal operation, the UPS load will be fed from the Inverter with the bypass switch inhibited. The Converter, apart from providing DC power to the Inverter, also charges the battery under the float charge mode. The battery charge system shall have float charge, equalizing charge and recovery charge modes, to replenish the batteries self-discharging part while the battery is fully charged, equalizing the battery cell voltage to a constant value forcibly and recharging the battery system to the required values when the batteries have been used, respectively. b) The Inverter shall constantly monitor the AC source frequency and shall be in synchronization with the AC input source till the frequency of the AC input source is within synchronizing limit and if the frequency of the standby source exceeds the synchronizing limit the Inverter will work on its own internal oscillator maintaining an output frequency of 50 Hz +/- 0.01% under all conditions of load. When the Inverter operates on its internal oscillator, it shall continuously monitor the frequency of the input source and when the input source frequency returns to within synchronization limit, the Inverter shall automatically synchronize itself with the input A/C source frequency and use it as a signal for Inverter output frequency control. c) Battery Operation:  When the A/C input voltage drops below specified limits or in case of a power failure the Inverter continues to supply AC power of constant voltage and constant frequency utilizing the battery system as a power source until the input voltage returns to normal requirement. When the power supply is resumed or the input voltage returns to limits, the Converter shall automatically start and the load fed for normal operation status.  If the power failure continues beyond battery back up time or the battery voltage drops to the final discharge voltage, the Inverter should automatically stop and at the same time transferring the load to the bypass circuit. On resumption of power supply, the Converter shall automatically re-start the operations and charge the batteries whereas the Inverter should inhibit automatic start and should be started manually. 495

7.14.37 Bypass Operation:

When power is supplied from the Inverter in synchronization with the bypass, it shall accomplish the following: a)

When the UPS output current reaches overload status it shall automatically transfer the load to bypass circuit with no interruption and when the overload status is cleared it automatically re-transfers the load to Inverter.

b)

When the battery final discharge condition is reached, the load shall automatically be transferred to the bypass circuit without interruption.

c)

In case of failure of the UPS, the load shall be automatically transferred to the bypass circuit with no interruption and when the failure is cleared, re-transfer the load to the Inverter shall be done manually.

d)

There should be provision made in the system to prevent, when necessary, asynchronous transfer.

e)

When the UPS goes on bypass mode in any of the conditions described above and if at that time there is no bypass power supply available due to power failure, the UPS shall remain in standby mode and as soon as the bypass power supply is available will transfer the load to bypass.

f)

A maintenance bypass transfer switch shall be provided with lock and key arrangement and should be manually done by authorized personnel only.

7.14.38 Cabinet And Enclosures

a)

The entire UPS system, including all components like inverter, static switch, maintenance bypass, shall be housed in free-standing steel type factory-finished enclosures complying with the protection standards of IP20. The enclosure shall be open able using a special tool for internal access. The colour shall be light grey. b) Ventilation Forced air-cooling shall be provided to allow components to operate within their rated temperature specified. The cooling fans shall have thermal relays protection using a latched cut fire re-setting, as a protection for the cooling fans. Similarly, the backup battery system shall also be housed as described earlier in an IP20 cabinet. 7.14.39 Control And Monitoring

a)

b)

The UPS shall utilize state of the art full DDC control software driven Control and Monitoring System. For UPS less than 40kVA software of lower version may be given. It shall be provided with LED displays. The display system shall have, as a minimum individual LEDs with different colours for the following:  Load on Inverter  Battery operation  Load on Bypass  UPS failure  LCD failure  Overload 496

c)

The UPS logic should provide one set of normally open dry contact / relay output to allow interfacing of UPS operating status to an external system and should be capable of providing, as a minimum, 10 numbers status and, should the UPS manufacturer‟s standard product does not provide such software, the bidder must add additional equipment and cost for the same. d) The UPS shall also have an RS232 port for interfacing to BAS system or client's centralized computer network. 7.14.40 LCD touch panel a)

The UPS shall be provided with a operator friendly large scale LCD touch panel.

b)

The LCD touch panel shall also include graphic measurement display, operational procedures of each activity, fault status display and also have capability to record at least 50 faults.

It should be possible to operate the entire UPS system and its components and obtain all measurements and data through the touch screen operation. The measurement software should provide capability to measure phase voltage, current in each phase, frequency, power factor, available battery time etc.

e)

Under all operating conditions, the system software should have capability for displaying fault alarm automatically. The tenderer should describe in detail the faults that would be displayed under this mode.

7.14.41 UPS Testing

a)

b)

c)

The Contractor shall perform the following tests, as a minimum, at site prior to handing over, to confirm the functional and the performance specification of the UPS as specified. All required test equipment like Digital Oscilloscope, Voltage Regulator, Measurement Meters, required artificial load etc. shall be the responsibility of the Contractor without any additional cost. The Contractor shall demonstrate as a minimum the following features on site by providing all required test equipment, such as power factor improvement, input current THD, output voltage THD, output frequency and all other performance monitoring requirements detailed before as required by the Employer. Warrantee/ guarantee certification shall be submitted by Contractor. Testing procedure is to be given by vendor and approved by Engineer incharge.

497

7.15 LIST OF ACT / BYE LAWS

The installations shall also be governed by the following Acts/Bye-laws/Codes as amended upto date in addition to the codes specified in the tender:

All spares and maintenance tools and tackles shall be designed to enable maintenance to be carried out in the least time and at the least cost and support resources without affecting the performance and safety aspects.

b)

For all major equipment including pumps, fans, drives, heat exchangers and large valves etc., appropriate structural steel members shall be provided for mounting various handling devices which are necessary for the dismantling and re-assembly of the equipment components during maintenance.

c)

All the spares and maintenance tools and tackles supplied shall be new and unused.

d)

The VENDOR/CONTRACTOR shall guarantee that before going out of production of spares and maintenance tools and tackles for the equipment furnished, he shall give at least 12 months advance notice to the EMPLOYER, so that the latter may order his requirement in one lot, if so desired.

7.16.2 SPARES

The BIDDER shall include the following three (3) categories of spares in his scope of supply. a)

START-UP AND COMMISSIONING SPARES Spares required for start-up and commissioning of the equipment, plant or system shall be indicated by the BIDDER in „Schedule of Start-up and Commissioning Spares‟. Total value of such spares shall be included in the quoted price for supply or erection of the equipment, plant or system. No additional amount is payable to the CONTRACTOR for equipment, plant and system for which erection and commissioning is in the CONTRACTOR‟s scope..

b)

All spares supplied shall be strictly inter-changeable with the parts for which these are intended to be replacements. The spares shall be treated and packed for long term storage under the climatic conditions prevailing at the site e.g., small items shall be packed in sealed transparent plastic bags with desiccator packs as necessary.

c)

Each spare shall be clearly marked or labelled on the outside of its packing with its description and purpose. When more than one spare is packed in a single case, a general description of the contents shall be shown on the outside of such case and a detailed list enclosed. All cases, containers and other packages shall be suitably marked and numbered for the purposes of identification. 499

7.17 Approved Make of Electrical Component/Equipment :

NOTE: - All materials and products shall conform to the relevant standards and shall be of approved make and design. A list of manufacturers/ vendors is given separately herein below for guidance. The Engineer shall give the approval of a manufacturer/ vendor/ only after review of the sample/ specimen. In case the same is not available in the market or in case of change in trade name, equivalent makes/ re-designated manufacturer then an equivalent approved make shall be used with the approval of Employer/ Engineer. The complete system and installation shall also be in conformity with applicable Codes & Standards and Tender specifications. - Only “First” class quality materials shall be used. - Employer reserves the right to choose any of the approved make / vendors as per this list. - In case of products not indicated in this list, bis marked products shall be preferred. - Specification of manufacturer‟s item shall be checked against tender item / specifications before selecting any product or brand name. In case of any discrepancy, tender item/ specifications shall prevail, and any such brand of item shall not be used which is not conforming to tender specifications even if it is listed in this list. - For use of material from a bis listed/ certified manufacturer, the contractor shall furnish a copy of the BIS certificate to Employer before procuring the material. - In case non-availability of any item/ material among approved manufacturers/ brands at a particular site/ region, alternate manufacturers/ brands conforming to BIS/ BS etc. shall be used subject to approval by Employer. - In case of non-availability of any manufacturer among approved manufacturers at a particular site/ region, alternate manufacturer‟s name shall be proposed along-with required credentials for Employer‟s approval. - In case of any item/ product neither covered in this list nor having A BIS specifications, the contractor shall submit the proposed item/ product along-with technical details/ specifications (as per bid), test certificates etc. And other credentials of the manufacturer for Employers approval. LIST OF APPROVED MAKES FOR PRODUCTS AND MATERIALS FOR ELECTRICAL WORKS ARE INDICATED IN THE TABLE BELOW. HOWEVER, ANY OTHER MAKE WHICH IS EQUIVALENT AND MEETING THE TENDER SPECIFICATIONS ARE ALSO ACCEPTABLEWITH PRIOR APPROVAL OF THE ENGINEER Sl. No.

8.1.1.1. This specification covers the requirement for design, engineering, manufacturing,

testing at Vendor‟s/Sub-Vendor‟s works, supply, packaging, forwarding, delivery at site, unloading from carriers, storage at site, transport to site, loading, unloading, installation, commissioning, carrying out performance guarantee / acceptance tests at site of field instruments and Integrated Building Management System (IBMS). Scope shall also include laying of cabling, necessary for installation of the system as indicated in the specification and Bill of Quantities. Any openings/chasing in the wall/ceiling required for the installation shall be made good in appropriate manner. 8.1.1.2. The BIDDER shall be a recognised leader in integration of IBMS system and capable

of supplying all necessary support services including hardware & software support, configuration services, system installation, commissioning & maintenance support. At least One- (1) no. of similar installations of the IBMS offered by the BIDDER should be in continuous operation for a minimum period of one year. 8.1.1.3. Microprocessor based Integrated Building Management System (IBMS) with

functions distributed both geographically and functionally over the field controllers shall be provided. IBMS shall comprise of Direct Digital Controllers (DDC), IBMS server and IBMS operator station. The field instruments for HVAC system shall be supplied, installed, monitored and controlled by the vendor. 8.1.1.4. HVAC system, the Fire Detection & Alarm System (FDAS), Access Control System

(ACS), Public Address System (PAS), CCTV system, DG sets, UPS, Energy meters and all other utilities and systems as Fire Fighting System, Waste Water Treatment plant shall be integrated with the IBMS system, monitored and controlled from Fire Command Centre room located at Ground floor in the Administration block. 8.1.1.5. It is not the intent to specify completely herein all details of design and construction

of equipment or materials to be supplied or of services to be rendered. However, the equipment, materials and services shall confirm in all respects to high standards of engineering design, workmanship and be capable of performing in continuous commercial operation in a manner acceptable to EMPLOYER who shall interpret the meaning of drawings and specifications and shall have the power to reject any work or material which in his judgement are not in full accordance therewith. 8.1.2

Codes and Standards

8.1.2.1. All equipment, systems and works covered under this specification shall comply with

all currently applicable statutes, regulations, standards and safety codes in the locality where the equipment shall be installed. 8.1.2.2. In particular, the following standards are applicable

NEMA : National Electrical Manufacturer‟s Association NBC: National Building Code GRIHA : Green Rating for Integrated Habitat Assessment 8.1.2.3. Other national standards established to be equivalent or superior to the codes and

standards specified are also acceptable. The BIDDER shall furnish English translation of all standards specified in this specification. 8.1.2.4. In the event of any conflict between the codes and standards referred to in the

specification and the requirements of this specification, the more stringent of these requirements shall govern. 8.1.2.5. Unless indicated otherwise, all codes and standards referred to in this enquiry

specification shall be understood to be the latest version on the date of offer made by the Bidder. 8.1.3

System Description

8.1.3.1. Integrated Building Management System (IBMS) shall be a microprocessor based

system with functions distributed both geographically and functionally over the field controllers. IBMS shall be PC based system allowing full seamless integration of following: a)

Energy Management.

b)

Utility Services such as Water Treatment Plant, fire fighting system etc,

c)

DDC/Converters for Software Integration

d)

DDC‟s for Ventilation system

e)

Fire Detection & Alarm System

f)

Public Address System (PAS)

g)

Access Control System (ACS)

h)

DG set

i)

CCTV system

j)

Uninterruptible Power Supplies (UPSs)

All the above systems shall be integrated and monitored from the IBMS supervisory workstations. 8.1.3.2. IBMS server will be placed in the server room located at Second floor in the

Administration block whereas workstations will be placed in the server room located at Fire command centre, Ground floor in the Administration block. 8.1.3.3. Building Management System DDCs shall have facility to connect any standard

analog and digital Input / Outputs. Such as 4 to 20 mA, 0 to 10V, RTD and potential free contacts. 20% of used channels installed / wired spares shall be provided while sizing / selecting the DDCs. Energy Management functions such as duty cycling and optimisation for controlling AC&V equipment shall be done in optimum manner. 8.1.3.4. The supply & installation of the DDCs is in the BIDDER‟s scope. 8.1.3.5. These

DDCs shall be interfaced with the IBMS system over MODBUS/LON/BACNET protocol and necessary hardware & software required in IBMS for interface shall be provided by the bidder. 507

8.1.3.6. Also the communication cables for interfacing the DDCs to IBMS system shall be

provided by the bidder. 8.1.3.7. DDC shall have the following software features as minimum: 8.1.3.8. Energy management and Control Programs and Associated Data files shall be in non-

TP shall consist of daily, weekly and annual programs plus a “TODAY” temporary function. DAILY Programs shall be definable for day types such as working day, half day, holiday, weekend etc. Each daily program shall allow a list of time based Analog and Digital commands to be used to user selected plant elements and points. WEEKLY programs shall allow a user selected set of daily programs to be defined for each day of the week (MONDAY through SUNDAY). The ANNUAL program shall initially be an Automatic Compilation of 52 weekly programs. Selecting a date of the ANNUAL Program shall allow modification of the daily selection entered into the weekly program (such as changing JAN 26 from working day to a Holiday). Control Application Software for DDC shall be customised strictly to meet the detailed requirements of the „Sequence of Operation” specified.

All DDC control software shall be designed via a graphic programming facility.

8.1.3.12. 8.1.3.13.

IBMS Software shall include the following as minimum features:

a) Microsoft Windows-based operating system. b) User Friendly Graphical interface providing a complete overview of all the systems connected to the IBMS system. The graphics should be universally understood. c) Seamless Integration of the various systems provided in the plant d) Measured values, operating status of drives displayed in real time e) Facility to be provided to the operator to adjust Set point from screen. f) Alarms displayed in real time, can be acknowledged & reset by operator from screen g) Time Scheduling – Time programmes shall ensure that HVAC & lighting are switched off automatically at the end of the day & during holidays. Apart from a 7-day programme, exception programmes shall also be made as required h) Historical Trending i) Report Generation – Provides a snapshot of the systems at any specific time or when specific events occurred. j) Access of viewing to only authorised users by provision of password at various levels. k) Separate screens shall be developed for operation and monitoring of each system. IBMS shall have capability to develop minimum 250 nos. of screens. l) Facility shall be provided to monitor and control all the systems from any IBMS operator station. 508

m) Facility shall be provided to configure the software for any addition / deletion of data from any IBMS operator station. n) General arrangement drawings and architectural drawings for each building will be made available to the CONTRACTOR by client. CONTRACTOR shall develop complete 3D view of the buildings displaying location of each equipment such as VRF‟s, cameras, access controlled doors, DG sets, stores, receptions etc. 8.1.4

System Specification

8.1.4.1. Air Conditioning

a) Variable Refrigerant Flow System (VRF) Variable Refrigerant Flow System is monitored and controlled through soft integration using RS 485/MODBUS communication. There shall be total five nos. of VRF controllers for Training & Production Block, Admin Block and Dining Block. 

Time scheduled based operation



Remote start/stop of each VRF unit through BMS.



Monitor the status of each VRF unit through BMS and keep a log of the number of hours run.



Monitor the space temperature through BMS & give an alarm for a high/low space temperature.

b) Scrubbers There shall be total two nos. of scrubbers for Dining Block. 

Time scheduled based operation



Start/stop of each fan through BMS.



Monitor the status of each fan through BMS and keep a log of the number of hours run.

8.1.4.2. Electrical System

a) Monitor one no. of Incoming medium voltage breaker (HT) status b) Monitor two no. of outgoing low voltage breakers (LT) status. Keep provision for monitoring of one no. of outgoing low voltage breakers (LT) status for future. c) Tentatively 14 nos. of energy meters will be provided. However exact quantity and location will be finalised during detail engineering. The Supply and installation of above system is not in the bidder‟s scope. These energy meters shall be interfaced with the IBMS system over MODBUS/LON/BACNET protocol and necessary hardware & software required in IBMS for interface shall be provided by the bidder. Also the communication cables for interfacing the energy meters to IBMS system shall be provided by the bidder. This shall mainly focus on the integrated system as a whole for energy conservation at gross level whereas network operation monitors each utility. Electrical management shall be taken care i.e. the following parameters shall be monitored that contributes to the cost of electrical energy.  Power (KW) 509

     

Power factor Energy (KW H) Demand Voltage Current Frequency

d) UPS will be provided at various locations depending upon the load requirement for reliable backup supply. Two nos. of UPS shall be provided in Utility building and two nos. of UPS shall be provided in Admin Building. The supply & installation of UPSs is not in the BIDDER‟s scope. However these UPSs shall be interfaced with the IBMS system over MODBUS/LON/BACNET protocol and necessary hardware & software required in IBMS for interface shall be provided by the bidder. Also the communication cables for interfacing the UPSs to IBMS system shall be provided by the bidder. 8.1.4.3. Plumbing System

a) Monitor Hi/Lo level at One no. of Underground Domestic water tank b) Monitor Hi/Lo level at One no. of Underground Flushing water tank c) Monitor Hi/Lo level at 11 nos. of Overhead Domestic water tank d) Monitor Hi/Lo level at 11 nos. of Overhead Flushing water tank e) Monitor and control 11 nos. of solenoid valve based on Overhead Domestic water tank level. If water is at high level setpoint, then valve shall closed, whereas if water is at low level setpoint, then valve shall open. f) Monitor and control 11 nos. of solenoid valve based on Overhead Flushing water tank level. If water is at high level setpoint, then valve shall closed, whereas if water is at low level setpoint, then valve shall open. g) Monitor and control 2 Duty +1 Standby Domestic water pump based on Overhead Domestic water tank level and solenoid valve command. If all Domestic water tank level is at High setpoint and all solenoid valves are command to close, then duty pumps shall command to stop. If any of Domestic water tank level is at Low setpoint and any of solenoid valve is command to open position, then duty pumps shall command to start. h) Monitor and control 2 Duty +1 Standby Domestic water pump based on Overhead Flushing water tank level and solenoid valve command. If all Domestic water tank level is at High setpoint and all solenoid valves are command to close, then duty pumps shall command to stop. If any of Domestic water tank level is at Low setpoint and any of solenoid valve is command to open position, then duty pumps shall command to start. 8.1.4.4. Fire Fighting System